Looking back on this unfortunate incident I would like to get a better understanding of what actually should have happened in terms of a safety stop. Air permitting should we have done the stop for 3 minutes? Or was it the right thing to get to the surface right away when sharing a single tank?
How many minutes of gas did you and the DM have at 20 feet when you had 1500 psi? How many psi do you think you would be consuming per minute?
How many psi per minute would you be consuming on the surface for both of you, stressed?
How far off do you think your gauge is, when it gets near zero?
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With an Al80, you had 38 cu ft of gas left at 1500 psi.
At 20 feet and a 2.0 combined SAC rate you would have been using 3.2 cu ft / min
You had around 12 minutes of gas at 20 feet, or were using 125 psi / min
At the surface you would have had 19 minutes of gas, or would have used it at a rate of 75 psi / min.
So, with 1500 psi, you could have stayed at depth for 3 minutes consuming about 375 psi of gas, to leave 1125 psi. At the surface that would 1125 psi would have lasted 15 minutes.
Even assuming that the last 500 psi of your tank could not be trusted you had 8 minutes of time at 20 feet until hitting that limit... or after doing a 3 minute stop at 20 feet, you had 8 minutes of gas left to sort things out at the surface before hitting 500 psi.
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You had quite a lot of gas left, and gas goes very slowly at the surface or at 20 feet.
You still had enough gas left to do a safety stop and deal with a problem at the surface, even assuming gauge error.
How could you have communicated to the DM that you had enough gas and that you wanted to complete the safety stop? Probably the best idea is to simply show your gauge to the DM and then signal to 'level off' -- of course if the OOG diver still thumbs you at that point you probably have to assume some other kind of issue...
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One thing you apparently did right was to get off the bottom promptly and not waste your gas futzing around deep and having your computer get annoyed at you at 40 feet was probably okay, provided that you could get your buoyancy together by 20 feet and arrest the ascent. That prompt ascent from the bottom set you up for having enough gas to complete the safety stop.