What can happen if a regulator is over tightened?

When a regulator is over-tightened, one significant risk is that the aluminum casing can crack. Regulators are typically designed with specific tolerances, and excessive force applied during installation or maintenance can surpass these tolerances. Aluminum, while lightweight and durable, is not as forgiving to stress as some other materials. When the casing cracks, it can lead to gas leaks, which undermine safety and necessitate the replacement of the regulator. This type of failure compromises not only the unit’s function but also poses a significant hazard in environments where flammable gases are present.

In contrast, while over-tightening can lead to other issues like seizing or operational restrictions, those tend to be secondary phenomena that do not result in immediate structural failure like a crack would. Therefore, the primary concern with over-tightening a regulator made of aluminum is indeed the risk of cracking.