A gas cylinder safety checklist is a walk around every place a site keeps or uses compressed gas: the cylinder cage behind the shop, the oxygen and acetylene cart, the nitrogen bottles in the lab, the propane cylinders on the forklifts. A cylinder holds a lot of energy in a small steel shell. Knock the valve off and it can travel like a missile; let it leak in a closed room and the gas can burn, poison or suffocate. This checklist records what gases are on site and then scores what you can see — restraint, caps, labels, segregation, regulators, hoses, transport and the leak plan — so every failure becomes a finding with an owner. Fill it in here and download a PDF without an account, or speak while you walk, and the document writes itself.
Start with an inventory
Before judging anything, write down what is there: each gas, how many full and how many empty cylinders, and where they sit. An inventory turns up the cylinder nobody has used in three years, the rental bottles that should have gone back, and the toxic gas that was ordered once for a single job and never left.
The inventory also decides which questions follow. A store of argon and nitrogen does not need the oxidizer separation checks; a site with oxygen and acetylene does, and so does any site with propane.
Upright, restrained, capped
Most cylinder accidents start with a cylinder falling over. Each cylinder should stand upright and be held by a chain, strap or rack so it cannot tip, whether it is full, empty, in storage or in use. A protective cap belongs on every cylinder that is not connected to a regulator, because the valve is the weakest part and the one that fails when a cylinder hits the floor.
Look at the cylinder itself too: dents, gouges, bulges, rust pitting, fire or arc damage, and the test date stamped on the shoulder. A damaged or out-of-date cylinder goes back to the supplier rather than into service.
Keep incompatible gases apart
Oxygen and other oxidizers make a fire burn far more fiercely, so they are stored away from fuel gases such as acetylene, propane and hydrogen. US rules for general industry set a separation distance or a fire-resistant barrier between the two; local fire codes may add more. Toxic and corrosive gases have their own storage rules and often need a ventilated cabinet.
Full and empty cylinders should also be kept in separate, marked groups. An "empty" cylinder still holds some gas at low pressure, and a mixed group means someone eventually connects an empty bottle in the middle of a job or sends a full one back.
Cylinders in use, and on the move
Once a cylinder is connected, the regulator, hoses and fittings become the hazard. The checklist asks whether each regulator suits the gas, whether connections are made without adapters, whether hoses are sound, and whether leak checks are done with a leak-detection solution rather than a flame. Valves are closed when work stops.
Cylinders are moved on a hand truck made for them, chained in, with the cap on — never rolled on their sides, dragged, or lifted by the cap. Carried in a vehicle, they ride upright, secured and ventilated, and come out at the end of the trip.
Common questions
How should gas cylinders be stored?
Upright and restrained, with caps on when not connected, in a dry, ventilated place away from heat, ignition sources, exits and vehicle traffic. Oxidizers are kept apart from fuel gases, full cylinders apart from empty ones, and the area is signed with the gases stored there.
How far apart do oxygen and fuel gas cylinders need to be?
Under US general industry rules, stored oxygen cylinders are kept at least 20 feet from fuel gas cylinders, or separated by a noncombustible barrier at least 5 feet high with a fire rating of at least half an hour. Check the local fire code, which may ask for more.
Can gas cylinders be stored lying down?
Cylinders of liquefied gas such as propane and acetylene must be kept upright, or liquid can reach the valve. Most other compressed gases should be stored upright as well, because a cylinder on its side is easier to roll or strike. Some supplier racks are designed for horizontal storage of specific gases; follow the supplier's instructions.
How do I check a cylinder connection for leaks?
Brush or spray a leak-detection solution on the connection with the gas on, and watch for bubbles. Never use a flame. If a leak does not stop when the connection is tightened, close the valve, move the cylinder outdoors if it is safe to do so, tag it and call the supplier.
Who should do this inspection, and how often?
A supervisor, safety officer or the person responsible for the gas store, typically monthly and whenever a new gas or storage area is added. Cylinders connected for use are also checked by the user before each shift.
Does completing this checklist make the site compliant?
It records what was checked and found on the day, and who signed it. Whether a store meets a particular regulation or fire code is judged against that rule by someone competent to do so.