To a person desensitised, accustomed or addicted to chilli, the directly proportional increase by using linear scaling would most likely be tolerable or possibly even enjoyable and expected. On the other end of the scale the resultant dish would probably be completely unpalettable. SS, your explanation of cooking 2 small dishes and combining them is valid, as is your suggested explanation of the change in cooking conditions due to increased volume. It may well be the case that the direct doubling of chilli simply isn't necessary, as opposed to incorrect and damaging, although there is ample anecdotal and instructional discussion to suggest otherwise. In bulk cooking, it is common practise to follow the non-linear increase in spices. This does not include all spices but it isn't restricted to chilli. I've previously found information related to this and listing other spices that are often scaled non-proportionally. Cinnamon, nutmeg, cardamom and vanilla for example. Some would include Cumin as well.
Nearly 4 years ago I was asked to do a bulk cook of several dishes for 40 people and as they were mainly children with disabilities, it was requested that the curries be mild. I did a lot of research at the time, found the information relating to the rule of X1.5 per double volume, experimented with it and ended up following that approach. The resulting dishes were exactly what I was aiming to achieve and when I'm asked to do it again in 6 months, i will again be using non-linear scaling.
Base gravy is possibly not the best object for this discussion. Low level if any chilli and I'm still presently of the opinion that because of this, base gravy is able to be scaled proportionally.