Prevent Tank Explosions – How to Keep Yourself and Others Out of Harm’s Way

The scuba diving industry justifiably takes pride in the outstanding safety record of scuba diving cylinders. Most of the credit goes to the voluntary inspection programs developed and implemented in the diving community all over the world. But all is not well.

Some years ago, it was discovered that aluminum cylinders made of a certain alloy would develop neck cracks over time while in normal service. Safety bulletins went out, inspectors increased their efforts to detect cracks, defective tanks were withdrawn from service and, in most cases, replaced at no charge to the owner. This particular alloy has not been used by the major cylinder manufacturers since 1988, nor by any manufacturer after 1990. Luxfer, the world’s largest manufacturer of aluminum cylinders, issued a voluntary recall of these cylinders and replaced them at no charge.

Now the problem has resurfaced. Although these older aluminum cylinders have passed both hydrostatic testing and visual inspections over the years, age and metal fatigue are now causing cracks to develop in some of these cylinders. The problem is more common with cylinders used in warmer dive areas. Usually the neck cracks are discovered during a visual inspection or when the tank develops a leak; rarely do the cylinders rupture. When they do rupture, it is usually during the filling process and it is the dive store staff who are most likely to be injured.

What Should You Do?

If you own an aluminum cylinder with a manufacture date of 2000 or earlier, here’s what you should do:

- Don’t try to decipher the specs or serial number on the cylinder yourself.
- Go to your local dive store and have it visually inspected.
- Ask the inspector to look especially for neck cracks. Most stores will do this visually, which is reasonable and effective. There are also new electronic testers available that do an even better job, but they’re still very uncommon.
- If there is any evidence of cracking, remove the cylinder from service.
- If the visual inspection is inconclusive, have the cylinder hydrostatically tested. If it passes that test, then have the visual inspection repeated.

Don’t Get Tanked

High-pressure cylinders are serious pieces of equipment, but they’re reliable and safe if you follow these eight rules of cylinder handling:

1. Have it inspected at least once a year; more often if it sees continuous use.
2. Have it hydro-tested every five years or whenever the cylinder has been subjected to any damage or high heat or if it shows signs of excess wear.
3. Rinse with fresh water after each day of diving.
4. Do not let the cylinder be overfilled.
5. Store the cylinder in an upright position whenever possible, making sure it will not fall.
6. Leave only a small amount of air in the cylinder when storing.
7. Always transport the cylinder in a secure manner, being sure to protect the valve from damage.
8. Check regularly for cracks or leaks yourself.

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