Universidad Carlos III de Madrid Bachelor Thesis Bachelor's Degree in Aerospace Engineering AIRBUS 320 Cabin Layout Passenger Arrangement Reconfiguration. Author:Juncal Mart´ınezSarri´on Tutor: Pablo Fajardo Pe~na AIRBUS 320 Cabin Layout Passenger Arrangement Reconfiguration. Abstract . This project was developed during a design engineering internship at SIRIUM AEROTECH and consists in the cabin layout passenger arrangement reconfiguration of an Airbus 320 aircraft in order to reduce the number of passenger seats from 174 to 162 and the final certification of the modification by means of EASA regulations. First of all, there is an introduction explaining the goals of the project and its background, as well as an analysis of the socio-economic impact. Secondly, it is found an inventory of all the materials involved in the project and the accomplishment instructions to carry out the whole modification. Thirdly, a flammability test is performed in order to prove the fire resistance of materials that will be used to manufacture some parts needed for the change. After that, manufacturing instructions are presented. Finally, the results obtained and the regulatory framework with the instructions for certi- fying the project are presented. This is followed by a time schedule and budget of the project and the conclusions. 1 AIRBUS 320 Cabin Layout Passenger Arrangement Reconfiguration. Acknowledgements First of all, I would like to thank Alejandro Rubio and the entire team of Sirium Aerotech for giving me the opportunity of developing this project in the company's facilities and for teaching me so much during my internship. Secondly, I would also like to thank Pablo Fajardo Pe~nafor his advice and continuous interest in helping me along the growth of the project, as well as to all the professors who, throughout the course, have helped me to acquire the academic and interpersonal knowledge that has made it possible to place myself at the end of this stage. Thirdly, I would like to express an infinite gratefulness to my mother, Isabel, since without her unconditional support from the first day until the last one, it would not have been possible to get where I am now. At last but not least, I would like to extremely thank Raphael Motta Costa for continuously encouraging and easing me with the difficulties passed during this last year of university. 2 AIRBUS 320 Cabin Layout Passenger Arrangement Reconfiguration. List of acronyms All the acronyms found along the project are listed in this section, alphabetically ordered: FAP: Forward Attendant Panel. AFM: Aircraft Flight Manual. HIC: Head Injury Criterion. AMC: Acceptable Means of Compliance. ICA: Instructions for Continued Airworthiness. APRB: Approval Sheet. IPC: Illustrated Parts Catalogue. AMM: Aircaft Maintenance Manual. JAR: Joint Aviation Requirements. AWM: Aircraft Wiring Manual. LOPA: Layout Passenger Arrangement. CAM: Cabin Assignment Module. MC: Mean of compliance. CB: Conversion Bulletin. MDL: Master Data List. CCL: Compliance Checklist. MDL: Master Data List. CCL: Compliance Checklist. MFCT: Manufacturing Instructions. CG: Center of Gravity. NSFSB: No Smoking/Fasten Seat Belt. CIDS: Cabin Intercommunication Data System. P/N: Part Number. CLAS: Classification Assessment. PA: Passenger Address. CLAS: Classification Assessment. PAX: Passengers / Persons / Occupants. CMM: Component Maintenance Manual. PBE: Personal Breathing Equipment. DEU: Decoder/Encoder Unit. PSU: Passenger Service Unit. DOA: Design Organization Approval. PTP: Programming and Test Panel. DOP: Design Operating Pressure. SC: Special Condition. DWG: Drawing. STC: Supplemental Type Certificate. EASA: European Union Aviation Safety Agency. TC: Type Certificate. ELT: Emergency Locator Transmitter. T/C: Tourist Class. ELT: Emergency Locator Transmitter. TCDS: Type Certification Data Sheet. EPA: European Part Approval. TP: Test Plan. ESF: Equivalent Safety Finding. TR: Test Report. EWIS: Electrical Wiring Interconnection Sys- tems. TSO: Technical Standard Order. FAA: Federal Aviation Administration. WBM: Weight & Balance Manual. 3 AIRBUS 320 Cabin Layout Passenger Arrangement Reconfiguration. Contents Abstract 1 Acknowledgements2 List of acronymns3 1 Introduction 7 1.1 Goals of the project...................................7 1.2 Background of the project...............................8 1.3 Socio-economic environment.............................. 10 1.3.1 Impact of the project.............................. 10 1.4 Aircraft Manuals.................................... 11 2 List of materials 12 2.1 Material to be removed................................. 12 2.1.1 LOPA / Interior Arrangement Configuration................. 12 2.1.2 PSU....................................... 14 2.2 Material needed..................................... 15 2.2.1 LOPA / Interior Arrangement Configuration................. 15 2.2.2 PSU....................................... 15 2.2.3 Emergency Equipment............................. 17 2.2.4 Floor Covering................................. 18 2.2.5 Curtains..................................... 19 3 Weight and Balance Study 19 4 Accomplishment instructions 19 4.1 Removal of the CAM.................................. 20 4.2 Removal of passenger seats............................... 20 4.3 Installation of CAM.................................. 21 4.4 Carpet and curtain replacement............................ 21 4.5 Installation of passenger seats, PSU arrangement and emergency equipment.... 21 4.6 Functional Checks.................................... 22 5 Vertical Testing 24 5.1 Test Plan........................................ 24 5.1.1 Specimen conditioning and configuration................... 24 5.1.2 Definitions.................................... 25 5.1.3 Apparatus.................................... 25 5.1.4 Vertical Test Procedure............................ 25 5.2 Test Results....................................... 26 5.2.1 Measurements for Carpets Material...................... 26 5.2.2 Measurements for Curtains Material..................... 27 6 Manufacturing Instructions 27 6.1 Material Information.................................. 27 6.2 Tooling.......................................... 27 4 AIRBUS 320 Cabin Layout Passenger Arrangement Reconfiguration. 6.3 Accomplishment Instructions............................. 28 6.4 Manpower........................................ 30 7 Results 31 7.1 162 pax Seats Arrangement Configuration...................... 31 7.2 PSUs Layout...................................... 35 7.3 Emergency Equipment Location Diagram....................... 40 7.4 Floor Covering Layout................................. 42 7.5 Curtain Installation................................... 47 8 Certification regulations. 50 8.1 Design Organization Approval............................. 50 8.2 Documentation..................................... 51 8.2.1 Compliance Checklist - CCL.......................... 51 8.2.2 Classification Assessment - CLAS....................... 59 8.2.3 Master Data List - MDL............................ 61 8.2.4 Test Plan and Test Report - TP & TR.................... 61 9 Time organization and budget 62 9.1 Time organization.................................... 62 9.1.1 Analysis of the problem............................ 62 9.1.2 Design of the results.............................. 62 9.1.3 Study of the regulatory framework...................... 62 9.1.4 Accomplishment of flammability test..................... 62 9.1.5 Report writing................................. 63 9.1.6 Breakdown of the time study......................... 63 9.2 Budget.......................................... 64 10 Conclusions and future work. 65 References 66 5 AIRBUS 320 Cabin Layout Passenger Arrangement Reconfiguration. List of Tables 1 Relation of figure1 items with seats P/Ns......................8 2 Seats to be removed................................... 13 3 PSU items to be removed................................ 14 4 List of seats to be re-installed.............................. 15 5 PSU items to be added................................. 15 6 List of PSU items to be re-installed........................... 16 7 Emergency equipment to be re-installed........................ 17 8 List of carpet segments for installation......................... 18 9 List of curtains for installation............................. 19 10 Seat Assy's to be removed, located and routed to customer goods.......... 20 11 Test Results for P/N BWW69/2............................ 26 12 Test Results for P/N 2759LS700............................ 27 13 Material needed for manufacturing of carpets and curtains.............. 27 14 Relation between P/Ns and carpet sections in DWG04 (see section 7.4)...... 28 15 Relation between P/Ns and curtain items in DWG05 (see section 7.5)....... 30 16 Estimated man-hours for manufacturing........................ 30 17 Means of Compliance Classification.......................... 52 18 Basic questions for project classification........................ 60 19 Advance questions for project classification...................... 60 20 Total time of work.................................... 63 21 Budget of the project.................................. 64 List of Figures 1 174 pax configuration - rows 1 to 15 (left) and 16 to 29 (right) - extracted from (2).9 2 Two seat assemblies, (2)................................. 12 3 Cabin Intercommunication Data System (CIDS) Scheme............... 13 4 Passenger Service Unit parts, (25)........................... 14 5 European Part Approval (EPA) Marking....................... 29 6 Classification