Near Fatal Hypercapnia Incident due to Incorrect Equipment Assembly

GLOC

real name: Gareth Lock!
This was posted on the Diving Incident Yahoo Group and I gained permission from the diver to reproduce it on DISMS here https://www.divingincidents.org/incidents/149

In essence, incorrect assembly of Poseidon Mk VI which led to excessive CO2 which was partly detected during pre-breathe but was not recognised as such. Diver lost 'awareness' during descent and was rescued by buddy. Total dive time 3mins, max depth 17m.

I assembled the RB the day before the dive and conducted all of the electronic pre-dive tests with the exception of the compulsory pre-dive 5 minute CC pre-breathe. The machine was then shut-down and the battery removed. I was fully compos menti at the time of assembling the RB, however, I was on vacation at the time and may have been relatively more relaxed than usual.

On the following morning of the dive and prior to loading my kit onto the boat, I again conducted all of the electronic tests, followed by the 5 min CC pre-breathe in a seated position. I recall feeling slightly dizzy upon completing the pre-breathe. I commented on this to a highly experienced diver colleague of mine who had accompanied me to the dive site. However, it was early in the morning and I attributed this to simply pre-dive ‘expectation nervousness’, a little of which I normally have prior to any dive.

I then loaded my kit onto the boat and we departed for the dive site. Upon arrival the boat skipper appropriated us into groups according to the intended purpose of our dives. I was paired with two other experienced OC divers with whom I have done many dives in the past. I donned the RB and proceeded to operate it in CC mode. Everything felt normal.

Upon exiting the boat we proceeded to descend. I was slightly shallower, i.e. approximately 2m above, one of the divers with whom I was paired. During the descent I was monitoring my RB’s paddle computer until it indicated that the O2 set-point had changed to 1.0. I recall feeling somewhat odd during the descent. When we were near the bottom the diver below me was oriented with his back to the ground, which I could see approximately 2 m below him, and signalled to me requesting if I was OK. All of a sudden I felt extremely dizzy and in a frank panic state. Hyperventilation immediately set in along with a pounding heart. I recall trying to signal that I was not OK, but did not know how to signal that there was something very wrong with my breathing apparatus. I recall turning to ascend and knowing that I needed to bail out. I do not have a clear recollection of the actual procedure of bailing out to OC, although, given the design of the OC/CC lever on the mouthpiece assembly of this unit I must consciously have done so. The symptoms did not immediately abate and I had to concentrate all of my attention to try to slow down my breathing and to maintain an ascent at a controlled pace. I recall the diver below me coming to my assistance but I do not recall what he did. The onset of the symptoms was exceedingly rapid and I certainly had neither the time nor wherewithal to consider bailing out to my side-slung deco cylinder. I do not recall much of what happened during the ascent.

When we reached the surface I sort of came-to and then removed the mouthpiece from my mouth and proceeded breathing atmospheric air. I recall hyperventilating on surfacing and the symptoms gradually subsiding. Fortunately, the boat was close-by and I was able to rest while holding onto the side of the boat for a few minutes. With the skipper’s help I doffed the gear and climbed onto the boat.

Once in the boat I said to the skipper that we had only descended ‘approximately 3 m and that the whole thing had taken only a fraction of a minute’. I began mentally reciting what I had done during the assembly of the gear to try and understand what had happened. At that point I recalled that I had forgotten to place the inner lid onto the top of the scrubber canister during the assembly of the RB. This was subsequently confirmed when I got home later on. I attributed the symptoms to a ‘CO2 hit’ (acute hypercapnia) in view of the fact that the omission of the internal scrubber lid had resulted in a system in which there was no breathing circuit through the CO2 absorbent.


Lessons Identified by the Diver

1. ‘Confidence breeds carelessness’. Having assembled the RB many times I was not sufficiently fastidious. While I followed a checklist, for some reason I omitted to insert the scrubber lid in the requisite position. I cannot think of any logical reason why I would do this. It is particularly strange since upon arrival at my home the lid was located where all of the other components of the RB are also always located, i.e. it was clearly visible and present at the time at which I was assembling the RB. This behaviour is also out of character for me since I am employed as a scientist and tend to ‘detail obsessiveness’.

2. The 5 minute pre-breathe test can be passed on this unit even if the inner scrubber lid is omitted. While I did feel a little dizzy after the pre-breathe test this did not seem to be a serious problem at the time. It has subsequently been commented by diver colleagues of mine that this might in fact indicate a system design error. This is in view of the fact that the RB circuit may be physically assembled and closed without the lid in place. While the system formally requires the scrubber lid for CC operation there is also no subsequent electronic or other warning of any kind, should it have been omitted.

3. The onset of an acute CO2 hit is extremely rapid and nearly impossible to control. Apparently, all I was able to do was flip the OC/CC lever into the OC position although I have no actual recollection of doing so. I could under no circumstances have bailed out to my off-board cylinder. The onset of hyperventilation, a pounding heart and panic happened literally within a single breath. Hypercapnia also seems to result in short term memory loss since my recollection of the events clearly did not agree with either what was measured by my dive computer or observed by my fellow divers. The diver that assisted me said that I had what looked like a ‘seizure’. Further, the extremely rapid onset of the symptoms might in part be as a result of the increase in gas partial pressure after descending past 10 m depth.

4. I could not have independently controlled my ascent. According to my dive computer our ascent rate reached a maximum of 50m/min. As stated, the ascent was managed by another diver and was not really what I was able to control. It is impossible to say what the ascent would have looked like without his assistance. Had this CO2 hit occurred at the end of a multi-stage deco dive I would likely not be here to recount this story. Such an event would presumably have been an unwanted Xmas gift for my wife.

5. The OC diver that accompanied me did not know how to assist me. This occurred since we did not know with whom we were going to dive prior to the dive and there was insufficient time for me to indicate to the diver how to assist me should something transpire. Fortunately, it seems I had the sense to bail out to my back mounted diluent independently.

6. At the very least, solo RB diving lacks wisdom. The outcome of this incident would likely have been different had I been alone.

Obviously I will not make such a mistake again and I have successfully dived the MK-VI unit subsequently and do intend continuing to dive with RBs. However, being in possession of the knowledge regarding the dangers of CC diving apparently does not prevent them from occurring. Clearly, RB diving requires far greater vigilance than OC diving. It would also seem to me that the idea of ‘recreational’ rebreather diving is oxymoronic.


Regards
 
Glad to see it did not turn into a death or near death.
Forgetting a piece during assembly is easy to do.
If you set a section of your assembly bench for all the needed parts
it is easier to see if you have overlooked some bit.
I have followed this piece of advice from day one.
Well yesterday it did save me from a similar situation of the
above diver. I assembled my unit and did the negative test
which was fine. I then looked at my bench area and I see
the piece which connects the scrubber to the extreme head
on my unit. I was shocked but not overly surprised, just a
small change in my routine proved to be dangerous.

The point here is to put all the parts in one location so
if something is left out you can then spot it on your
bench and rectify prior to diving.

Gabe
 
Iv an old ybod with the old fiberglass case that s held on with 4 bolts , i like to use the back of the case to hold all the bits i remover from the breather .


if i take the scrubber and head say back to the hotel to dry and refill , i stick the O ring and spacer in the scrubber bucket , ready to refit next day or later the same day , up to now iv been ok ,

thanks for posting ,
 
Iv an old ybod with the old fiberglass case that s held on with 4 bolts , i like to use the back of the case to hold all the bits i remover from the breather .

Funny, I do exactly the same thing. I use the upturned case to hold all the parts I take off. It just seemed a sensible place to chuck everything.

Diver in the OP said:
The OC diver that accompanied me did not know how to assist me. This occurred since we did not know with whom we were going to dive prior to the dive and there was insufficient time for me to indicate to the diver how to assist me should something transpire. Fortunately, it seems I had the sense to bail out to my back mounted diluent independently.

That's one of the reasons why I never dive with OC divers when I'm on my box. It's a hell of a responsibility to put on someone, get a random stranger familiar enough with your kit and procedures to save your arse and expect them to remember it. It's really not their problem and I wouldn't expect someone with no CCR familiarity to take it on, for both mine and their sake. It isn't fair on either of us or (to my taste for risk) very sensible.
 
If you can leave a piece of your breather out (and still assemble the unit for a dive) and it gives a co2 bypass, i profer the rebreather has a shitty design.
 
If you can leave a piece of your breather out (and still assemble the unit for a dive) and it gives a co2 bypass, i profer the rebreather has a shitty design.

yep my old turd maybe a shitty design , but i only need to remember to put the o ring and spacer back in , im happy with that ,

it work,s just fine then, Id not say it has a assemble problem , but if i leave parts out i will get problems , o ring s bats and sorb .
if you for get to change them or dont put them back in , problems problems problems ,

do,s your ccr turn on the dill and o2 , for you , may want to look in to that . as i read lot,s of ccr divers have been killrd cos no unit gas turned on , shitty A
 
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I am amazed the " state of the art fulley automated safety features" of this unit didnt pick up on the problem??? (LOL)


ATB

Mark
 
If you can leave a piece of your breather out (and still assemble the unit for a dive) and it gives a co2 bypass, i profer the rebreather has a shitty design.

So every rebreather that has a removable scrubber? Except the explorer which does not let you breathe without one. I get what you are saying but you can't engineer everything out.


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Glad to see it did not turn into a death or near death.
Forgetting a piece during assembly is easy to do.
If you set a section of your assembly bench for all the needed parts
it is easier to see if you have overlooked some bit.
I have followed this piece of advice from day one.
Well yesterday it did save me from a similar situation of the
above diver. I assembled my unit and did the negative test
which was fine. I then looked at my bench area and I see
the piece which connects the scrubber to the extreme head
on my unit. I was shocked but not overly surprised, just a
small change in my routine proved to be dangerous.

The point here is to put all the parts in one location so
if something is left out you can then spot it on your
bench and rectify prior to diving.

Gabe

When we took over HH the first thing I did was add the string that holds the sensor cap on. Since we took over ever sensor cap to leave our factory is tied to the head so you can't forget it.


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Thank you for sharing. I feel like I need to read a certain amount of accounts like this each year to scare me back in to being careful.


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I am amazed the " state of the art fulley automated safety features" of this unit didnt pick up on the problem??? (LOL)
As others have alluded to, engineering & design are the first barrier when it comes to reducing incidents, but at some point users have to take personal responsibility for their actions. Some have derided checklists during assembly and final checks as not being required but yet we still have checklists for making sure an aircraft has its landing gear down. Therefore checklists are only of use if they are followed properly.

I have not seen the Mk VI PADI 'Advanced CCR' course materials and therefore I am not sure if it covers what to expect in terms of the effects of CO2.

The point for me is that there needs to be multi-layered approach to safety, be that good and effective training so that you understand the unit, what its limitations are, what the potential failure points are and how they are manifested to the diver and what to do in the event they occur. The lack of understanding by the buddy on what the system will be doing and how to rescue the diver is a failure point in the established team diving and buddy diving construct. A buddy can help prevent incidents from occurring and / or developing, they can also recover the diver/body (depending on how far things have gone).

Many on here will have developed their skills and knowledge over time and learned through experience, you cannot teach that experience on a course but only through reports like this do we get the message out.

Regards
 
When we took over HH the first thing I did was add the string that holds the sensor cap on.

A string, is that it, The first thing you did?

I guess that's the development budget for the HH blown.

"And for those wishing to have the custom option, we can supply a red coloured string."

A sort of "Redman" string can bus kind of snuff. :rolleyes: Iain
 
Thanks for sharing GLOC, well done to the buddy who undoubtedly saved a life that day and to the diver for reporting it.

I often dive with OC divers, some tech-minded, some not. It's hard to know how much to explain to a new OC buddy, but I have simplified my buddy check to something like this: ignore most of the stuff on my kit, it's actually not that different to yours; this is how you inflate my BCD, this is how you ditch my weights, if something bad happens try to keep my mouthpiece in my mouth and try to get me to the surface, slowly if you can but better bent on the surface than dead on the sea floor. I think this buddy and I would get along well!
 
I dived with a chap who prep'd his unit 5 days before diving but decided to keep the scrubber (Meg) in his hotel room - to keep it safe. It was still in the hotel room when he was a 3m. He came to the surface abruptly, and was spotted by a keen-eyed team member and picked-up.

I put the spacer and o-ring over the bucket handle also to help me remember - and I never assemble the thing unless I do it fully - with grease. Otherwise I leave it in bits.

Thanks for posting, interesting read.

Matt.
 
Scary account. It's very easy to forget a step in any procedure especially one you do just prior to something enjoyable like diving. This is something to consider when building your kit.


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Thank you for the detailed Incident report, GLOC. This is the kind of info I find extremely valuable on a forum. I am glad that this incident was managed and did not turn into an accident. I am impressed with the OC diver which managed the ascent, well done.

My thoughts as I was reading this:

1) This is the second Hypercapnia incident report which describes the rapid onset of symptoms. It confirms my opinion that every RB should feature a BOV; at least as an option.
2) I hope that a lot of R&D is put into the design of accurate CO2 analysers for rebreathers. We can measure everything that is life-threatening on RB's except CO2.
 
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3) This incident speaks strongly for the design of the EAC scrubber unit. The cartridge goes into the container, the lid is closed, the unit is pressure tested there and then and that is it. No small parts that can be forgotten or lost.
Apart from the inner scrubber lid which was missing and lead to the excessive CO2 in the loop...

Regards
 
3) This incident speaks strongly for the design of the EAC scrubber unit. The cartridge goes into the container, the lid is closed, the unit is pressure tested there and then and that is it. No small parts that can be forgotten or lost.

Why? This unit uses them and it didn't help at all.

It's not possible to make a unit that "just works" and requires "no skill" and where the electronics/design will _always_ save you.

Matt.
 
Matt, there would be, it would just be beyond the level of economic viability for the majority of divers.

Regards
 
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