The Department of Energy (DOE) is seeking commercial sources with the capability and experience to serve as a System Integration Contractor to design, develop, qualify, and produce Multi-Mission Radioisotope Thermoelectric Generators (MMRTGs) for use on future National Aeronautics and Space Administration (NASA) space exploration missions. The MMRTG would be suitable for use in various potential NASA space exploration missions, including missions to the surface of Mars (and potentially other planetary bodies) as well as in the vacuum of deep space. The MMRTG would use thermoelectric materials that have demonstrated extended-lifetime and performance, and would be sized for a heat source composed of eight (8) General Purpose Heat Source (GPHS) modules to provide 28 volts DC and approximately 110 Watts electric (We) at beginning of mission. Each GPHS module, fueled with plutonium-238 (Pu-238), will provide approximately 250 watts thermal (Wth) at the beginning of mission. The contemplated contractual effort consists of six separate phases. The Phase I effort will be focused on the analysis, design, development, fabrication, and testing of an unfueled Engineering Electrically-heated Thermoelectric Generator (ETG). This phase includes the development of design requirements and specifications for the MMRTG. The Contractor would test the Engineering ETG to support the design basis for the Flight MMRTG. As part of Phase I, the Contractor would demonstrate a qualified thermoelectric component fabrication and production capability to produce thermoelectric components to meet MMRTG design requirements and specifications and proceed to verify their performance, including accelerated testing to determine lifetime performance. The Contractor would develop analytical tools for performing safety analyses and prepare safety analyses to support ongoing NASA National Environmental Policy Act (NEPA) activities. The Phase II Option will be focused on the analysis, design, fabrication, and testing of a Qualification ETG that will be used to flight qualify the MMRTG for space missions. Based on the results of Phase I, the design requirements and specifications would be updated. The Contractor would complete the final design, fabricate, and test the Qualification ETG. Also as part of Phase II, the Contractor would demonstrate that the thermoelectric component fabrication process is qualified to produce high quality, uniform thermoelectric components that meet design requirements and specifications for various space exploration environments; fuel and test the Qualification ETG at the DOE fueling and test facility; and continue to perform safety analyses to support NASA?s NEPA activities and prepare a Preliminary Safety Analysis Report (PSAR) to support the interagency launch approval process for use of the MMRTG. The Phase III-V Options are for the production of Flight ETGs to achieve specific mission objectives. The Contractor would deliver government accepted Flight ETGs to the DOE fueling and test facility. These phases would include the spacecraft integration, preparation of a Final Safety Analysis Report (FSAR), and support of the launch approval and ground operations activities. The Phase VI Option will be for a spare Flight MMRTG and may be exercised in concert with the execution of the Phase III, IV, and/or V Options. DOE expects potential sources to have technical engineering expertise and project management capability and experience to: 1. Develop Requirements, Specifications and Test Plans for the Engineering, Qualification, and Flight ETGs and MMRTGs. 2. Develop qualification and acceptance test levels for the ETGs and MMRTGs. 3. Perform structural, thermal, and thermoelectric design analyses of the MMRTG in order to support a definitive design basis in such areas as system response to launch dynamic loads, heat source support preload, thermal interface definition, radiation properties, and handling requirements during and prior to launch. 4. Develop power predictions for various mission profiles, including various launch dates and mission durations. 5. Develop the design and establish engineering documentation for the MMRTGs and ground support equipment. 6. Demonstrate a thermoelectric component manufacturing capability for fabricating thermoelectric materials and thermoelectric components. Provide for the training and qualification of operators, supervisors, and inspectors. 7. Qualify the production facility and procedures by manufactureing qualification lots of thermoelectric components and by the fabrication and test of several qualification lots to determine lifetime performance. 8. Fabricate, assemble, and test an Engineering ETG to support the design basis for the MMRTG. 9. Fabricate, assemble, and test a Qualification ETG and ship to the DOE fueling and test facility for fueling and testing to qualify the MMRTG. 10. Provide technical review and oversight of the ETG/MMRTG handling, fueling, and acceptance testing at the DOE fueling and test facility. The Contractor would also interface with the various Government heat source production facilities. 11. Fabricate ground support equipment for the DOE fueling and test facility and use at the launch site. 12. Prepare safety assessments of the MMRTG and support analyses and documentation for the NASA NEPA Environmental Impact Statement (EIS) process based upon mission/launch vehicle databooks. Prepare Safety Analysis Reports and participate in the Interagency Nuclear Safety Review Panel (INSRP) reviews with DOE and NASA to obtain launch approval. 13. Prepare a Safety Test Plan and provide test hardware and engineering oversight for safety tests conducted at Government laboratories or elsewhere. 14. Provide launch site support for the receipt, storage, maintenance, and flight preparation of MMRTGs; spacecraft integration; support activities; and testing of MMRTGs. 15. Establish project management, project control and reporting, quality assurance, and environmental and reliability activities required for this effort. National, state, and local safety, health, and environmental laws would be adhered to in the manufacture of ETGs. The North American Industry Classification (NAIC) code for this proposed effort is 336415 and the small business size standard is 1000. This announcement is not a Request for Proposals (RFP) and shall not be construed as a commitment by the Government to award a contract or contracts at this time. All interested parties are hereby invited to submit a capability statement of no more than five pages to demonstrate their capability to provide the services stated above. All such capability statements shall be received via e-mail to the attention of Wayne Bryan at
contact@example.gov no later than 12:00 PM Pacific Daylight Time on April 19, 2002. Companies responding must indicate their business size. The Government will not pay for the provision of any information nor will it compensate any respondents for the development of such information. Definitions: The following brief description of hardware terminology is provided as an aid in understanding this sources sought notice: Converter - The assembly of the generator which includes all elements of the conversion device, namely housing, end covers, thermoelectric components, insulation assembly, heater/heat source support systems, ancillary gas management, electrical power circuitry, instrumentation, and all other parts excluding the isotope heat source. Converter fabrication is the system Contractor?s responsibility. ETG - Electrically-heated Thermoelectric Generator - is comprised of a Converter and electrical heat source integrated assembly. The ETG is the Contractor?s major assembled product. MMRTG - Multi-Mission Radioisotope Thermoelectric Generator - is comprised of a Converter and isotope heat source (i.e., GPHS modules). The MMRTG is derived from an ETG via a fueling operation conducted at the DOE fueling and test facility. The fueling operation includes removal of the electrical heat source and replacement with a government furnished heat source assembly. Acceptance testing of the MMRTG is conducted by the DOE fueling and test facility.
