Compressed gas cylinders store contents at pressures up to 2,500 psi and present serious hazards including explosion, asphyxiation, toxic exposure, and fire if improperly handled or stored. A cylinder that falls and shears its valve can become a projectile traveling at tremendous speed. OSHA 29 CFR 1910.101 requires employers to visually inspect all compressed gas cylinders under their control and to handle, store, and use them in accordance with Compressed Gas Association (CGA) standards. This guide covers the complete inspection requirements with a free downloadable checklist.
Free Compressed Gas Cylinder Inspection Checklist
Download our Word document checklist covering cylinder condition, valves, storage, labeling, and transport.
Download Checklist (.docx)Regulatory Requirements
OSHA 29 CFR 1910.101 — Compressed Gases (General Requirements)
- 1910.101(a): Each employer shall determine that compressed gas cylinders under their control are in a safe condition to the extent determinable by visual inspection. Inspections shall follow DOT Hazardous Materials Regulations (49 CFR 171–179) or CGA Pamphlets C-6 and C-8.
- 1910.101(b): In-plant handling, storage, and utilization of all compressed gases in cylinders shall be in accordance with CGA Pamphlet P-1.
- 1910.101(c): Compressed gas cylinders must have safety pressure relief devices.
CGA Pamphlet P-1 — Key Storage and Handling Requirements
- Cylinders shall be stored upright and secured to prevent falling (chains, straps, or racks).
- Valve protection caps shall be in place when cylinders are not connected for use.
- Cylinders shall not be stored near heat sources or where temperatures exceed 125°F.
- Incompatible gases shall be separated (oxygen from fuel gases by 20 feet or a 5-foot fire-resistant barrier).
- Storage areas shall be permanently posted with the names of gases stored.
- Cylinders shall not be dropped, struck, or used as rollers or supports.
Never attempt repairs: Do not repair or alter cylinders, valves, or safety relief devices. All repairs must be performed by the compressed gas supplier. Do not tamper with safety relief devices. Do not repaint cylinders without authorization from the owner, as color codes are used for gas identification.
Cylinder Condition
| Inspection Item | What to Check |
|---|---|
| Cylinder body | No dents, bulges, gouges, cuts, or excessive corrosion. No arc strikes or torch burns. No evidence of exposure to fire or extreme heat (distorted shape, discolored paint, melted fittings). |
| Hydrostatic test date | Cylinder within requalification period (typically stamped on shoulder: month-year with star or plus sign). DOT 3AA cylinders typically require retest every 5 or 10 years depending on markings. |
| Valve and fittings | Valve not bent, broken, or leaking. Valve handwheel present and operable. No cross-threaded connections. CGA outlet connection appropriate for the gas type. |
| Valve protection cap | Cap in place and threaded on securely when cylinder is not in use. Cap not stuck due to corrosion (do not force — contact supplier). Cap threads not damaged. |
| Safety relief device | Relief device present and intact. No signs of tampering. Not plugged, capped, or obstructed. Frangible disc or fusible plug in good condition. |
| Foot ring / base | Foot ring (if equipped) intact and not bent. Cylinder stands upright without leaning. No damage that prevents secure placement in cylinder stand or rack. |
Labeling and Identification
| Inspection Item | What to Check |
|---|---|
| Contents identification | Cylinder clearly labeled with name of gas contents. Label legible and not obscured by paint or damage. Color coding matches contents (if color coding system is used). |
| Hazard warnings | GHS/HazCom label present with appropriate hazard pictograms, signal word, and precautionary statements per OSHA 1910.1200. |
| Status marking | Cylinder marked as Full, In Use, or Empty (MT). Empty cylinders clearly identified and segregated from full cylinders. "Empty" or "MT" tag attached to valve. |
| Owner identification | Cylinder ownership markings visible. Do not use cylinders from unknown sources. Do not deface or remove any markings, stamps, or labels. |
Storage Area Conditions
| Inspection Item | What to Check |
|---|---|
| Securing | All cylinders secured upright with chains, straps, or cylinder racks. Each cylinder contacts at least 3 surfaces if using nesting method. Securing at approximately 2/3 height of cylinder. |
| Separation of gases | Oxygen separated from fuel gases (acetylene, propane, hydrogen) by minimum 20 feet or by a 5-foot noncombustible barrier with fire rating of at least ½ hour. |
| Environmental conditions | Storage area well-ventilated. Protected from weather and direct sunlight. Temperature maintained below 125°F. Away from continuous dampness, salt, or corrosive chemicals. |
| Location safety | Storage does not block exits, stairways, or egress paths. Away from elevators and high-traffic areas. Area posted with names of gases stored. "No Smoking" signs posted where flammable gases are stored. |
| Fire protection | Storage area away from combustible materials. No ignition sources nearby for flammable gas storage. Fire extinguisher accessible. Sprinkler heads not obstructed (if equipped). |
Welding operations: For cylinders used in oxygen-fuel gas welding and cutting, additional requirements under OSHA 1910.253 apply. Acetylene cylinders must be stored valve end up. Oxygen and fuel gas cylinders must be separated by 20 feet or a 5-foot fire-resistant barrier. Cylinders must be kept far enough from welding operations to avoid sparks, hot slag, or flame contact, or protected by a fire-resistant shield.
Corrective Actions
Remove from Service When:
- Cylinder is leaking from valve, body, or safety relief device
- Cylinder shows evidence of fire damage, heat exposure, or physical abuse
- Cylinder is past hydrostatic retest date
- Contents cannot be positively identified — label missing or illegible
- Valve is damaged, inoperable, or connections are cross-threaded
- Safety relief device is missing, damaged, or has been tampered with
- Cylinder has excessive corrosion, dents, bulges, or gouges
Download the Free Checklist
Get our compressed gas cylinder inspection checklist in Word format. Customize for your storage areas and gas types.
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Compliance Calendar
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Task Management
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Training
Track employee training on compressed gas handling, storage, and emergency response.
