regulator hose leak

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Russoft

Contributor
Messages
233
Reaction score
113
Location
Minneapolis
# of dives
50 - 99
This isn't a near miss, but a lesson learned. It could have been a near miss had I been deeper, or panicked, I suppose. It occurred this past weekend and I just thought I'd share a real life equipment failure. I know that for me, equipment failures during a dive are largely just a figment of my imagination. It's always a "what if" but never actually happens. Equipment problems, when they occur, are obvious before I ever descend to the bottom. This reminded me that equipment can and actually will fail during a dive.

I bought a couple new braided flex LP hoses. One went onto my wife's primary regulator. She has jaw/neck issues and, as I expected, the flex hose helped her hugely as the regulator wasn't being wrenched from her mouth constantly. This weekend I put my octo/back up on a regulator necklace and put my primary on my octo hose so it could be donated. The other flex hose replaced this latter hose. I included an elbow joint at the regulator.

We were diving a quarry and were at a depth of 7 m / 23 ft. My primary regulator started to bubble constantly. I thought it was free flowing. I removed it and saw bubbles coming from the hose connection point. I signaled the problem to my wife and took her octo. I signaled her to switch off my air so I could attempt to repair the problem - hand-tighten a loose connection. No joy, I needed a wrench to work on it. When she turned my air back on, bubbling got worse, so I signaled her to switch off my air again. We ascended to the surface with me breathing on wife's octo. I orally inflated my BCD at surface and we swam back to entry point.

The problem ended up being a broken o-ring on the end that inserts into the regulator (or in this case, the elbow joint). Now, I don't know why an o-ring on a brand new hose would fail so quickly, but I didn't have a spare. So I replaced the entire hose with my old hose (which was showing signs of wear but still worked fine). That solved the problem. We managed to still get two dives out of the day despite our first aborted dive.

A few observations. This is a good reason not to make too many changes to equipment between dives. Better to test each modification individually, where possible. Don't assume new equipment is in working order. Don't do a demanding dive without testing your equipment first. Know where o-rings are and check their integrity prior to installing new hoses, etc. Remaining calm helps you think clearly when something goes wrong under water. I might have become panicky if we'd been deeper and this occurred. I'm glad I had to deal with this problem in shallow water so if I experience it at depth in the future, I can react appropriately. Finally, I learned that while I can reach back and touch my tank valve, touching and manipulating are two very different things. I had to rely on my wife to fiddle with the tank valve. Finally, always have spares. This is the second major equipment failure I've encountered on a dive trip this summer and both times I only saved the dive because I had the right spares.

A few questions. Is it wise to shut off air at depth? In hindsight, I might have been in real trouble had I become separated with my wife during ascent as she had the only working regulators. Perhaps I let my desire to save the air in my tank (so I could continue my dive later) to over rule the safest course of action: Ascend with my air on. We were shallow, but deep enough to drown! What likely resulted in a failed o-ring that should be brand new? Is it possible to pinch the o-ring while making the hose connnection? Is it possible that I didn't tighten the connection properly and the o-ring was pushed out of it's seat? I also realize I failed to lube the o-ring prior to installing the hose. The o-ring had a good chunk missing out of it, only 3/4 of it remained.
 
A few questions. Is it wise to shut off air at depth?

No. Not at all in single-tank recreational diving.

As you now know, not only does turning the air off NOT HELP... but it has the potential to exacerbate the underlying issue.

Plus, as you've correctly pointed out, if you got separated from your wife you'd have been in real trouble.

You should have switched to your OWN alternate while checking to see if hand-tightening the hose on your primary would correct the problem. If it didn't (as in this case) then end the dive on your own alternate, with your wife at the ready to donate if needed.


---------- Post added September 21st, 2015 at 12:18 PM ----------

This is the second major equipment failure I've encountered on a dive trip this summer

This was not a "major equipment failure" by any stretch of the imagination.

A leaking low-pressure hose is a nuisance.

---------- Post added September 21st, 2015 at 12:20 PM ----------

What likely resulted in a failed o-ring that should be brand new?

Could have been nicked originally. You could have nicked it installing the hose. Hopefully you didn't cross-thread anything. However, if this were the case you should have noticed the issue as soon as you turned the tank on, long before entering the water.

My guess (since you didn't notice it before entering the water or immediately upon descent) would be that you didn't tighten the hose enough. After a bit, the o-ring was forced out of place by the pressure. Depressurizing and repressurizing the system deformed/worsened the o-ring issue even more, as you saw when you turned the tank back on.

If the

---------- Post added September 21st, 2015 at 12:21 PM ----------

Tbut I didn't have a spare. So I replaced the entire hose with my old hose...

Yes you did. It was on the "old hose" that you re-installed. Could have easily swapped that o-ring to the new hose. However, you probably did the right thing since at that time you didn't know what caused the o-ring to fail.
 
Last edited:
This isn't a near miss, but a lesson learned. It could have been a near miss had I been deeper, or panicked, I suppose. It occurred this past weekend and I just thought I'd share a real life equipment failure. I know that for me, equipment failures during a dive are largely just a figment of my imagination. It's always a "what if" but never actually happens. Equipment problems, when they occur, are obvious before I ever descend to the bottom. This reminded me that equipment can and actually will fail during a dive.

I bought a couple new braided flex LP hoses. One went onto my wife's primary regulator. She has jaw/neck issues and, as I expected, the flex hose helped her hugely as the regulator wasn't being wrenched from her mouth constantly. This weekend I put my octo/back up on a regulator necklace and put my primary on my octo hose so it could be donated. The other flex hose replaced this latter hose. I included an elbow joint at the regulator.

We were diving a quarry and were at a depth of 7 m / 23 ft. My primary regulator started to bubble constantly. I thought it was free flowing. I removed it and saw bubbles coming from the hose connection point. I signaled the problem to my wife and took her octo. I signaled her to switch off my air so I could attempt to repair the problem - hand-tighten a loose connection. No joy, I needed a wrench to work on it. When she turned my air back on, bubbling got worse, so I signaled her to switch off my air again. We ascended to the surface with me breathing on wife's octo. I orally inflated my BCD at surface and we swam back to entry point.

The problem ended up being a broken o-ring on the end that inserts into the regulator (or in this case, the elbow joint). Now, I don't know why an o-ring on a brand new hose would fail so quickly, but I didn't have a spare. So I replaced the entire hose with my old hose (which was showing signs of wear but still worked fine). That solved the problem. We managed to still get two dives out of the day despite our first aborted dive.

A few observations. This is a good reason not to make too many changes to equipment between dives. Better to test each modification individually, where possible. Don't assume new equipment is in working order. Don't do a demanding dive without testing your equipment first. Know where o-rings are and check their integrity prior to installing new hoses, etc. Remaining calm helps you think clearly when something goes wrong under water. I might have become panicky if we'd been deeper and this occurred. I'm glad I had to deal with this problem in shallow water so if I experience it at depth in the future, I can react appropriately. Finally, I learned that while I can reach back and touch my tank valve, touching and manipulating are two very different things. I had to rely on my wife to fiddle with the tank valve. Finally, always have spares. This is the second major equipment failure I've encountered on a dive trip this summer and both times I only saved the dive because I had the right spares.

A few questions. Is it wise to shut off air at depth? In hindsight, I might have been in real trouble had I become separated with my wife during ascent as she had the only working regulators. Perhaps I let my desire to save the air in my tank (so I could continue my dive later) to over rule the safest course of action: Ascend with my air on. We were shallow, but deep enough to drown! What likely resulted in a failed o-ring that should be brand new? Is it possible to pinch the o-ring while making the hose connnection? Is it possible that I didn't tighten the connection properly and the o-ring was pushed out of it's seat? I also realize I failed to lube the o-ring prior to installing the hose. The o-ring had a good chunk missing out of it, only 3/4 of it remained.

First of all, I try to always have my tank positioned so I can manage the valve myself, without my buddy needing to be involved. I'm guessing you damaged the o-ring on installation. Forgetting to lube it could cause the damage, as could pinching it.
 
interesting...thanks for sharing..
 
This was not a "major equipment failure" by any stretch of the imagination.

You're right, I guess what I meant was an equipment failure bad enough to end the dive had I not brought spares.

Yes you did. It was on the "old hose" that you re-installed.

I didn't have the tools to remove the o-ring from the old hose. I was afraid of damaging it in the process so figured the old hose was a safer bet. After this I'll be buying an o-ring kit with a pick for removing them.
 
Interesting, I had almost this exact same thing occure to me a week ago. Diving in the St Lawrence, I suddenly had a lot of bubbles coming from my primary reg. Upon inspection I found the regulator was coming unscrewed from the hose. I switched to my secondary and shut down the post. Being on doubles I could shut down, in your case however on a single I would leave that open and manage the freeflow situation as best as possible, saving going to your wifes octo if you finally drained your tank, or could not longer get any air at all. I have become more and more of an advocate for carrying a ( even small) pony bottle for singles divers. I have to say since getting into tech and diving doubles, man that redundancy is really nice to have.
 
We were diving a quarry and were at a depth of 7 m / 23 ft. My primary regulator started to bubble constantly. I thought it was free flowing. I removed it and saw bubbles coming from the hose connection point. I signaled the problem to my wife and took her octo. I signaled her to switch off my air so I could attempt to repair the problem - hand-tighten a loose connection. No joy, I needed a wrench to work on it. When she turned my air back on, bubbling got worse, so I signaled her to switch off my air again. We ascended to the surface with me breathing on wife's octo. I orally inflated my BCD at surface and we swam back to entry point.

The problem ended up being a broken o-ring on the end that inserts into the regulator (or in this case, the elbow joint). Now, I don't know why an o-ring on a brand new hose would fail so quickly, but I didn't have a spare. So I replaced the entire hose with my old hose (which was showing signs of wear but still worked fine). That solved the problem. We managed to still get two dives out of the day despite our first aborted dive.

That type of failure often occurs when the connection comes loose and blows the o-ring out of the gland it sits in. This does not happen until it actually comes a couple turns loose. That is, hand tight or slightly loose will not result in a leak. But, once it starts leaking, you can bet the o-ring is no longer in the groove. Retightening at this point is what cuts the o-ring as it is not in the gland. The leaking connection must be shut down and depressurized. Then loosening the connection just a bit should allow the o-ring to pop back into the groove. If it does, it will be very simple to tighten the connection by hand. If it is at all difficult to tighten, then the o-ring has not gone back into the gland or has already been damaged.

FWIW, I would have no problem making that repair at depth as long as I had a reliable alternate air source. Better yet, prevent such a mishaps by checking those connections, by hand, as you set up your gear.
 
I can't think of many situations where you would shut down your tank. Even if it's leaking heavily it's still the only source of air "connected" to you and even with most connection failures you can still breath off it. Hell, even if your reg was shredded right on off the hose you can still sip gas. At 23 ft, not that big of deal to surface, but as mentioned if for whatever reason you got separated from your buddy and were deep, well that's a whole different story.

I think it's worth mentioning that if you have any failure with connections on your hoses, whether minor or catastrophic, you can simply just crimp the hose with your hand to stop the air from leaking. No different than a garden hose. This may be an important thing to remember if you're deep, on the backend of your dive where every cubic foot is important to safely get you to the surface, perhaps your buddy isn't there or doesn't notice the issue and maybe you pushed the limits and really need to perform a safety stop. Of course this all assumes you're breathing off your octo.

Crimping the hose is not something I've had to experience but I was told it works by my instructor. And I can't think of reason why it wouldn't. Sometimes we just have to dumb down what may appear to be a complicated situation.
 
A suggestion would be to invest in a torque wrench for proper tightening. I am not a fan of the hand tight then a 1/16 of a turn, or whatever archaic way they use to use. I think we started to use torque values post WW2. An improperly torqued bolt or nut will either back out or distort the threads.
 
https://www.shearwater.com/products/swift/

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