High-Pressure Hose injuries

This operator was fortunate to avoid a worse outcome
CREDITS | Text by Francois Burman
A lurking peril
PEOPLE WHO HAVE FILLED scuba cylinders, refilled oxygen cylinders, or boosted a gas mix are familiar with using flexible hoses. Some hoses are covered with a durable rubber or thermoplastic jacket, while others appear even sturdier with a braided stainless-steel mesh on the outside. Correctly specified hoses are rated to pressures of up to 6,000 psi.
When we first learn the basics of high pressures in hoses and cylinders, we are aware of the potential for serious injury to ourselves and those around us. If hoses fail, the results can be ear-shattering sounds, parts as projectiles, or an escaping gas stream that is strong enough to take out an eye. Without suitable restraints, hoses can whip around with sufficient force to amputate a limb.
Complacency often takes over in most cases, as hoses are sturdy and designed to be handled frequently and subjected to all kinds of abuses. But the risks never diminish, only our perception of risks.
The keys to hose safety are regular inspection, competent use, and replacement according to the manufacturer’s guidelines. Hose replacement is necessary with regular use and should occur more frequently with high usage or in humid areas where metals corrode easily.
The DAN Risk Assessment Guide for Dive Operators and Dive Professionals, which is available as a free download on DAN.org, contains a series of recommendations to address these risks. This information relates to selecting materials and manufacture, hose installation and use, and inspection and maintenance.
A lurking peril
PEOPLE WHO HAVE FILLED scuba cylinders, refilled oxygen cylinders, or boosted a gas mix are familiar with using flexible hoses. Some hoses are covered with a durable rubber or thermoplastic jacket, while others appear even sturdier with a braided stainless-steel mesh on the outside. Correctly specified hoses are rated to pressures of up to 6,000 psi.
When we first learn the basics of high pressures in hoses and cylinders, we are aware of the potential for serious injury to ourselves and those around us. If hoses fail, the results can be ear-shattering sounds, parts as projectiles, or an escaping gas stream that is strong enough to take out an eye. Without suitable restraints, hoses can whip around with sufficient force to amputate a limb.
Complacency often takes over in most cases, as hoses are sturdy and designed to be handled frequently and subjected to all kinds of abuses. But the risks never diminish, only our perception of risks.
The keys to hose safety are regular inspection, competent use, and replacement according to the manufacturer’s guidelines. Hose replacement is necessary with regular use and should occur more frequently with high usage or in humid areas where metals corrode easily.
The DAN Risk Assessment Guide for Dive Operators and Dive Professionals, which is available as a free download on DAN.org, contains a series of recommendations to address these risks. This information relates to selecting materials and manufacture, hose installation and use, and inspection and maintenance.

Hose restraints on both ends can dramatically reduce the consequences of failures.
Image by Brandon Brownell
Image by Brandon Brownell
Some key recommendations for hose safety include the following:
- Keep flexible hose lengths to a minimum. Using rigid pipes to reduce the length of flexible hoses is the best practice. Hoses should not exceed 6.5 feet and should always be fitted with restraints at the attachment points on both ends. Keep them away from occupied areas, and place long hoses in a protective conduit or covered channel.
- Choose hoses with antiwhip characteristics and kink-resistant materials suitable for high-traffic areas, abrasive contact, and typical dive environments. Their ratings should well exceed the maximum possible pressures generated by the equipment in use.
- A key component is how the end fittings are affixed to the hose. Purchase hoses from reputable suppliers, and have an inspection of end fittings at the top of your checklist.
- Regular inspection of a hose’s condition and monitoring the competence of people handling hoses will provide greater safety assurance.
- It is difficult to provide an absolute requirement, but good practice is to either inspect and hydrostatically test all gas hoses or replace them every five years, depending on the manufacturer’s instructions.
- Taking these steps will help you lower the risk of a serious accident. Hoses are usually designed for extreme use and are unlikely to fail if handled carefully, regularly monitored for condition, and replaced when they show warning signs of damage due to wear, corrosion, or excessively rough handling.
Categories
2023
January
March
Demo DiversCape Marine Research and Diver DevelopmentKaboom!....The Big Oxygen Safety IssueTerrific Freedive Mode“LIGHTS, Film, Action!”Scuba Nudi ClothingDive into Freedive InstructionThe Benefits of Being BaldThe Inhaca Ocean Alliance.Special Forces DiverToughing It Out Is DangerousWhat Dive Computers Don\'t Know | PART 2
2022
January
February
UNCERTAINTY AFTER DIVING: Case Report and Recommendations #1.UNCERTAINTY AFTER DIVING: Case Report and Recommendations #2UNCERTAINTY AFTER DIVING: Case Report and Recommendations #3UNCERTAINTY AFTER DIVING: Case Report and Recommendations #4DIVERS LOSING ACCESS TO EMERGENCY CAREPreventing Breathing gas Contamination
March
When Should the Rescue Begin?Celebrating Young and Old in Turks and CaicosScuba Cylinder RundownChasing WeedsUnderwater Smartphone PhotographyAir and a SpareUnderwater Photographer: Fred BuyleBuilding Better BalanceLow-Visibility DivingMore Than a Sore ShoulderNot Only for DivingLaryngospasm and AnxietyPulmonary Hypertension and DivingTitan Meets TitanicPool Operation: Know Before you GoThe Argonaut Octopus and the jellyfishShort but Beautiful Lives
April
A Sense of PurposeMexico’s Sardine RunHigh-Pressure Hose injuriesA Hole in My HeartGoing UpConcussion and Return to DivingMarfan Syndrome Recommendations.South African Sardine Run by Walter BernardisSouth African Sardine Run By ProdiveSardine Run Port Elizabeth by ProDiveSardine Run Port St Johns by ProDiveScuba Diving In MauritiusScuba Diving in TanzaniaScuba Diving in the SeychellesScuba Diving in Nosy BeScuba Diving in MalawiScuba Diving in KenyaScuba Diving in South AfricaScuba Diving in Mozambique
May
June
July
Destination AntarticaUnconscious DiverA Little DetailDive Boat SafetyBlenny Watching 101Bonaire Inspires Hope for the Future of CoralThe Secret to Deep Freediving: Tips from 3 Female World Record HoldersEnsuring Safety in Freediving CompetitionsFour Tips For Staying Warm While Cold Water DivingAnd They Dived Happily Ever AfterFreediving Is About To Enter A New Era If Oxama Has Its SayGET BENT!The Joys and Challenges of the DeepUnderstanding The Secrets of Deep Freediving: Tips from Three National Record Holders