I just thought I would add this point.
Regulators failures are rare, especially mechanical failures of the first stage. However, I have had a buddy have a catastrophic failure of a first stage, as others have also discussed here.
Most problems are either hose failures. Or Free flows.
Free flows are generally occur in cold water. This is due to ice forming, either in the second stage or first stage. The ice forces the valve open.
Ice formation is due to the gas freezing any water molecules in the air within the regulator. The gas temperature drops as the pressure drops from high pressure to low pressure through the first and second stages. This is what causes the freezing. First stages are designed to heat sink, actually warm the first stage from the surrounding enviroment. An issue with the early generation of composite material first stages was they failed to conduct the cold away from the internal mechanism and where more prone to freezing.
Thinks that significantly increase the risk of freezing are.
1. Cold regulators (storing them in the car overnight in cold weather).
2. Water vapour within the air in the cylinder.
3. High gas flows. (The faster -more- gas that flows through the first stage, the colder it will get and the increased risk of freezing).
4. Breathing off the first stage in very cold weather PRIOR to submerging (The exhaled breath introduces water vapour into the second stage, which is a potential freezing point).
Point 3 is important.
Venting a first stage, for a prolonged periods of time increases the risk of free flow. i.e. Filling a DSMB.
Heavy breathing increases the risk.
AND IMPORTANTLY - two people breathing off a first stage doubles the gas flow (even if they are both relaxed - the likely hood is the Out of Gas diver will have an elevated breathing rate). This significantly increases the likelyhood of a free flow in cold water.
A point to remember - once the second stage ices open, the first stage will ice open very quickly afterwards.
I have witnessed this issue a number of times.
Example 1.
Two Pairs started a 35m (105feet) dive in a freshwater quarry in February in cold fresh water.
Pair 1 one diver had a freeflow. He switched to his buddies AS. As they started the ascent, the buddies regulators started to free flow. The second pair assisted, each taking a buddy on to their AS. One diver immediately switched from his primary regulator to his pony. All four divers commenced the ascent.
At approximately 10m the pair sharing the same first stage had another free flow. They made the surface OK.
The other pair stopped at 10m did a short stop, then ascend. One on the pony, one on his buddies AS.
After exiting, checking they where all OK, they decided that any more diving was probably not advisable, so retreated to the pub.
Example 2.
On a winter dive. I looked up at my buddy, air was slowly dribbling from his second stage exhaust port. As I closed on him, the rate of air leaving the exhaust increased. As I presented my long hose regulator, his regulator disappeared in bubbles as the first stage iced fully open. We made a controlled ascent.
We dived a bit later having swapped to a new regulator set.
This is part of the reason British divers like their Twinsets (Doubles) or Pony's
