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S
cuba equipment failure or malfunction is
a relatively rare factor in diving-related
accidents and fatalities. When it does
occur, the most common and hazardous
malfunctions involve regulators and
buoyancy compensator (BC) power
inflators.
1
Thus, a recent report to DAN® of a regulator
failure was not necessarily surprising, but the cause in
this particular case turned out to be quite unusual.
Although the diver involved in the incident managed
the situation very well, and no one was harmed, an
inexperienced or nervous diver might not have been
so fortunate. It was particularly strange that although
the diver’s cylinder was not empty, the gas flow had
slowed and then ceased in a way that resembled
an out-of-air situation. Closer examination of the
equipment led to a puzzling discovery: A large amount
of yellow crystallized material was blocking the inside
of the braided second-stage regulator hose. The hose
had been in use for a few years but showed no external
abnormalities or signs of deterioration.
While trying to solve the mystery, we discovered this
was not an isolated case. The same situation occurred
July 22, 2015, and was reported subsequently in a
technical diving blog.
2
Further reports from a hose
manufacturer and at least one equipment-servicing
workshop in a popular diving region revealed that
these were not isolated events. Although no injuries
have been reported, the discovery prompted a wider,
global investigation, which is ongoing.
Analysis revealed the culprit to be a form of
polymorphic crystallization — a phenomenon associated
with cyclical heating and cooling at oil-water interfaces.
3
In both incidents, the crystallization seemed to be
related to the molecular structure of the internal tube.
The current theory is that repeated cyclical heating
and cooling of the hose lining promotes this form of
crystallization in materials either unsuitable for this
application or affected by certain chemicals or bacteria.
The sun heats the hose, then the flow of breathing gas
cools down the internal surface of the hose again. This
process recurs with each dive, and the crystals grow and
accumulate over time. Enough crystals eventually form
to encroach on the gas flow, or they migrate toward the
second-stage regulator, resulting in significant failure of
the breathing device.
So far the reported incidents have been in tropical
climates with gear that is several years old. We have
not received reports of this problem with vinyl hoses,
and given the number of braided hoses out there (both
as original components and replacement parts) the
incidence is likely quite small. But because this hazard
threatens divers’ air supplies, it is of great potential
interest to the dive community. The challenge is
determining how best to respond to this discovery.
It’s important to identify what divers need to know
right now as well as what precautionary maintenance
guidelines and early detection strategies they should
implement at this stage.
The standard safety recommendation regarding
regulator hoses has been that they should be
inspected regularly for signs of external deterioration.
Disintegration or abrasion of the outer rubber coating
eventually predisposes hoses to rupture during
pressurization or even when in use. Rubber hoses are
quite prone to this condition, which is why polymer-
braided hoses were developed. But herein lies the
problem: The outside of braided hoses can appear
108
|
WINTER 2017
GEAR
INVISIBLE
CRYSTALS
CRYSTALLIZED NYLON-
HOSE INTERIORS CAN
CAUSE REGULATOR
FAILURES.
By Francois Burman,
Pr. Eng, MSc
STEPHEN FRINK
Polymorphic crystallization
inside hoses has recently
emerged as a hazard divers
should be aware of.