What is the maximum fill pressure for Oxygen and Nitrox?

DOT regulations currently limit the oxygen fill pressure of aluminum and composite cylinders to 3,000 psi at 70F. There are no similar DOT fill pressure limits for compressed oxygen gas in steel cylinders, but as a practical matter pure oxygen fills exceeding 3,000 psi are highly unlikely, regardless of cylinder composition or service pressure. In the US, almost all bulk compressed oxygen available to local dive shops is aviation grade in steel DOT-3AA-2400 cylinders with a CGA-540 valve at a service pressure of 2,640 psi. Since most oxygen fills by local dive shops are done using the cascade method, a typical local dive shop pure oxygen fill in a rebreather or decompression cylinder will be between 1,800 psi and 2,400 psi unless the shop has an oxygen booster.

The DOT considers any gas containing more than 23.5% oxygen to be pure oxygen for the purposes of handling. Thus, knowledgeable fill station operators will not fill aluminum cylinders with Nitrox higher than 3,000 psi. This means the 3300 psi "compact" or "neutral buoyancy" aluminum SCUBA cylinders will receive a short fill. Again, there are no such restrictions on Nitrox in steel high pressure SCUBA cylinders with a service pressure of 3442 psi. Although there are some older steel SCUBA cylinders with a service pressure of 3500 psi, recent DOT regulations limit the transport of such cylinders to a maximum fill pressure of 3442 psi as well.

Published in: Oxygen & Nitrox