Anyone ever overfill 72s? My girlfriend and I have two we're about to double up.
I know down in cave country LP tanks are frequently overfilled to 3600, although I know they're "today's" LP tanks rather than yesteryear's, so they're stronger and have thicker sidewalls.
I've never taken these two 72s over ~2600-2700, and that's only when they're getting a faster than normal fill. Otherwise I like to keep it to 2500 max. We want these tanks to last forever, so overfilling and hot filling these aren't something we plan on doing.
The material on “today’s” 3AA tanks is not any stronger than those “old” tanks. Most 3AA tanks are made out of ASTM 4130 and the allowed stress of all 3AA cylinders during hydro testing is 70,000 psi (per CFR49, section 178.37).
Some of the newer 3AA cylinders are design to a working pressure of 2400 psi versus 2250 psi for the traditional 72 cu ft cylinder, but that is just a geometry change affected by the cylinder diameter and the wall thickness.
In general a hot fill will not deteriorate any steel cylinder. As a mater of fact you are allow to correct for temperature (overfill) as long as the pressure returns to the working pressure at 70º F (the maximum allowed temperature is 130ºF). If you do the math using ideal gas law you will see that at 130ºF the tank can be at 11% higher pressure than its rated pressure at 70ºF.
Therefore, since most of my tanks have passed the requirements and have been stamped with the “+”, their working pressure is 2475 psi. Under a hot fill they can go as high as 2747 psi (or 11% above working pressure). This is technically not a true overfill since it will return back to 2475 psi at room temperature.
I do not recommend over fills, but I am aware of many steel 72’s that have been used for years in the Florida cave region at pressures of 3000 psi. Statistically those thanks seem to pass hydro for a long time with out any signs of degradation.
Under highly controlled conditions overfilling a steel 72’s to 3000 psi is technically not detrimental to the integrity of the cylinder, since the test pressure is 3750 psi, but under real life conditions it is not leaving much of a safety margin. Material yield (in a structurally sound cylinder) should not start below the test pressure, but I do not recommend pushing it, especially not on a regular basis.
If on occasion a dive shop operator fills a steel 72 to 3000 psi by accident, I don’t worry about it. I would just make sure it doesn’t get any hotter before I dive it.