Autoclave Machine

• All surgical instruments that are in touch with open

wounds or enter the body of a patient must be sterile.
Therefore, all surgical instruments and materials have
to be sterilized before surgery.
• The machine which does the sterilization is called
autoclave or sterilizer.
• If sterilization does not happen or happens
insufficiently, life-threatening infections are the result.
For this reason the autoclave is one of the most
important pieces of equipment in a hospital.
 Cont.

• The medical steam autoclave is a device that uses pressurized,

high temperature steam to sterilize medical instruments.
Although there are still other methods of sterilization e.g. dry
heat, gas (Ethylene Oxide) or gamma radiation, the
sterilization with hot steam is the most common method.
• The usage is simple, rapid, cost effective and environment
friendly. The following article refers to the steam autoclave.
 Cont.

• Sterilization is the elimination of all transmissible micro

organism, bacteria, viruses and fungi from the surface of an
instrument.
• This is different from disinfection, where only organisms are
removed by a disinfectant and are not completely eliminated.
 Cont.
• In general, any instrument that enters the body must be
sterilized. This includes all surgical instruments, implants,
catheters, syringes, needles, dressings and others.
• Proper sterilization of instruments is crucial in preventing HIV
transmission.Sterilization is possible with hot air, chemicals or
radiation, but the most common method is the use of hot
steam, which kills all organisms. This method is easy and
cheap to realize.
 Cont.

• For a steam sterilization temperatures above 110°C are

needed, which requires the steam to be applied in a pressure
chamber.
• The sterilization time depends on the temperature.
• The higher the temperature the faster the instruments get
sterile.
 The principle of steam sterilization
• Water is heated up in the chamber. At 100°C steam develops
and after a short time the pressure increases, the boiling point
of the water rises and so does the temperature (heating phase).
• When the predefined pressure or temperature is reached the
heating element is switched off, either by a thermostat or a
pressure switch. In electronic controlled autoclaves a pressure
or a temperature sensor delivers a signal to the control board.
Cont.
 Cont.
• At this point the sterilisation phase begins. Then the
temperature drops a bit and the heating element is switched on
again.
• In this way the temperature is kept stable. At the same time a
timer gets started and after the set time the autoclave switches
off completely.
• The sterilisation process is now completed (drying phase), the
outlet valve opens and releases the steam.
 Cont.

• The sterilisation goods remain a little longer in the chamber

and the radiant heat from the chamber dries the items.
• The sterilisation time begins only when the sterilisation
temperature (121°C or 134°C) is reached.
 Types of autoclaves

• All steam autoclaves have a metal chamber to withstand the

high pressure and the temperature.
• A massive door or lid which is locked during operation keeps
the chamber closed. The chamber is heated by an electric
heating element.
• In places without electricity supply autoclaves heated up by
gas or fuel are common.
• To ensure that an autoclave works correctly, the machine has a
temperature and/or a pressure gauge and often an integrated
timer.
 Cont.

• Modern autoclaves are all electronically controlled.

• The control unit controls temperature, pressure and time and
monitors all safety functions.
• Hospital autoclaves are available with chamber capacities
from 5 l to 900 l.
• The smallest and simplest ones work manually and are heated
up by a normal electric or gas stove.
• The big stationary autoclaves are fully automatically
controlled and need three-phase-power supply and a water
supply installation.
 Vertical

• The vertical autoclave is a stationary top-loader with a

capacity of 60 l - 100 l. The vertical autoclave is often double
walled with pressure gauges, thermometer, water level
inspection tube and a mechanical timer.
• Bigger vertical autoclaves need 3-phase electrical installation.
Cont.
 Construction of vertical autoclave

• The typical vertical autoclave is manually controlled and very common

in smaller hospitals.
• The components are simple and can be repaired and replaced easily.
Such an autoclave consists of the following parts:
 Pressure control valve
• The pressure control valve opens when the working pressure (and thus
the temperature) is reached.
• It works with a counter weight or a spring and can be adjusted
manually.
 Air-removal valve
• Is opened manually when the sterilization process is finished. It releases
the steam out of the chamber.
• This can be done by opening a mechanical valve or by a solenoid when
pushing a switch.
 Cont.

 Thermometer or temperature gauge

• The thermometer shows the temperature
inside the chamber and thus indicates to the
user when the sterilization temperature is
reached and the sterilisation process can be
started.
 Safety valve
• The safety valve opens and releases the
pressure out of the vessel if the pressure
control valve fails and the pressure gets too
high.
• With pulling the safety valve also the steam
pulse can be applied (↑Steam-pulsing)
 Cont

 Pressure gauge
• The pressure gauge shows the
pressure in the vessel but is not
really needed when a
thermometer is built in.
 Lid and lid gasket
• A heavy lid closes the vessel
air tight. The lid is sealed with
a silicon gasket.
• The gasket has to be checked
and cleaned frequently.
• A leaking gasket allows hot
steam to escape and can create
serious burns.
 Cont.

 Heating element
• The heating element (sometimes
three elements for a three-
phases power supply) heats up
the water.
• It is important that it is always
covered with water. 3 phase heating element.
• A dry heating element will burn
out within seconds.

single phase
heating elemnt
 Cont

 Drain valve
• It is used to drain
remaining water from
the chamber after
sterilisation and
during cleaning.
 Cont.

• Some vertical autoclaves are double walled where the

sterilisation goods are not placed directly over the heated
water in the upstream steam but in another chamber.
• This inner chamber is placed in such a way, that the steam can
only enter from above. That helps to achieve a more
homogeneous and safer sterilisation result.
• Because the water level is no more visible in a double walled
autoclave, this type has a gauge glass that shows the water
level inside the outer chamber.
 Cont.

• Most of the autoclaves have an integrated timer.

• The timer starts when the sterilisation temperature is reached
and switches off the heating elements when the sterilisation
time is over.
• The timer is often a mechanical one, driven by a little motor. In
modern autoclaves the timer is a small electronic circuit.
 Table-Top Autoclave

• Table top autoclaves have a capacity of 20-80 l. Although it

has just small capacity, the table-top is the most common
autoclave.
• It is found where surgical instruments are needed: E.g. in
maternity wards, laboratories and at the dentist.
• Modern table-top autoclaves are a fully automatically
controlled, and often come with a vacuum pump and a drying
program for drying the goods after sterilisation.
• Table-tops are designed for front loading use and provide
different trays for surgical instruments. They also have a safety
lock for the door and a water reservoir.
Cont.
 Construction of Table Top Autoclave
• The valve 2 opens and water runs from the
reservoir 1 through a filter 3 into the
chamber 4. When the water level reaches the
level sensor 6 the valve closes and the heater
switches on 5. After a while, steam is
generated. The steam rises and pushes the
cooler air through valve 9 and the condenser
10 out of the chamber. When the
temperature reaches the boiling point
(measured by the temperature sensor 7), the
outlet valve 9 closes. Then the pressure in
the chamber rises (shown by the pressure
gauge 8) as well as the temperature. When
the sterilisation temperature is reached
(sensor 7), the heating element switches off.
• If the temperature control fails and the
pressure gets too high, the pressure is
released by safety valve 11. For cleaning and
servicing, the water can be drained by the
manual valve 12.
 Cont.

• In addition, modern table top autoclaves provide more safety

features like a door lock and an internal water tester
• Mechanical sensors and meters are replaced by electronic
ones. An electronic board or a microprocessor controls and
monitors the sterilisation process.
Cont.
 Cont.

Door lock / door switch

• Only after closing and locking the door properly can the
sterilizer be switched on. A micro switch at the door
mechanism gives the information to the electronic board and a
solenoid blocks or releases the door mechanism.
Level switch for water inlet
• A certain amount of distilled water is let into the chamber
automatically. The water intake is either time or level
controlled. In the second case a water sensor in the chamber is
needed. It is usually just a piece of metal that works as a sensor
together with a little electronic circuit.
• This circuit measures the electrical resistance between the
sensor and the chamber. When water reaches the sensor the
resistance becomes low and the electronics switches off the
inlet valve or the water pump.
 Cont.

• Temperature sensor
The actual temperature in the chamber is measured by a
temperature sensor. The sensor delivers the measurement to the
control unit. Here the actual and the pre-set temperature are
compared and a control voltage for switching the heating
elements is created.
• Chamber heating / thermal fuse
Often the outside of the chamber is also heated. This heating
supports the drying process after sterilisation.
This chamber heating is usually protected against over-heating by
a thermal fuse.
 Cont.
• Steam valve/exhast valve
After the sterilisation phase, the release valve (outlet valve)
opens. Steam gets out of the chamber, flows through a condenser
and gets back as hot water into the reservoir.
• Safety valve
The safety valve is designed to release steam in case the chamber
pressure is increasing beyond the normal range due to a fault in
the control elements. Without safety valve the chamber would
burst with catastrophic consequences.
 Stationary Type Autoclave

• Stationary autoclaves are big, automated or semi-automated

machines, built for all sorts of purposes: Instruments, liquids,
clothes and even for waste sterilisation.
• They are available with capacities up to 800 l.
• Stationary autoclaves are normally located in the sterile
processing department (SPD) of a hospital.
• Often the autoclaves have two doors, a front and a rear door
and are positioned between two rooms, a sterile and a non-
sterile area. Stationary autoclaves require plumbing and 3-
phase electrical installation.
 Construction of a stationary autoclave
• Large stationary autoclaves, especially when they consist of
several sterilisation chambers are run by steam from an
external water boiler
• The advantage is that hot steam is available immediately, the
pressure in the chamber builds up faster and the overall
sterilisation time gets shorter.
• When the sterilisation of one batch is finished, the next batch
can already be loaded and started.
Additionally, each chamber is surrounded by an outer shell, the
jacket.
• Here hot steam circulates and pre-heats the chamber before it is
used. Also the chamber is post-heated that way when the steam
is released out of the chamber after sterilisation. This prevents
water condensation and ensures a dry sterilisation result.
 Cont.

• When the inlet valve 1 is open, hot steam

from the external boiler enters the jacket
2 of the autoclave. The chamber gets
preheated. The pressure gauge shows 3
the jacket pressure. When valve 4 is
opened, the steam gets into the chamber.
The colder air escapes through the open
valve 6. The valve is a temperature
controlled one-way valve. The valve
closes when the steam is hot enough.
Now the pressure rises until it is as high
as the inlet pressure.
• The chamber pressure is shown by the
pressure gauge 8 and the temperature by
the thermometer 5. It is placed at the
bottom of the chamber, where the lowest
temperature is. When the sterilisation
 cont.

• The pressure and the temperature in

the chamber decrease but the jacket
is still under hot steam pressure.
This supports drying the load. After
a while the steam from the jacket
can also be released by opening
valve 4 or it can be kept if another
load has to be sterilized.
• The safety valve 9 opens when the
steam pressure is too high. In
principle this valve is not needed
because the boiler already contains
one and the pressure in jacket and
chamber cannot get higher than the
pressure in the boiler.
cont

1.Steam Trap
2. safty valve
3.exhast valve.
 cont.

Steam Trap:
• The Steam Trap has the very important
automatic,dual function of exhausting all
air from the sterilizing compartment, and
of making a suitable seal to allow a
pressure build-up of live steam during a
cycle of sterilization.
• Also, a slot is milled at an angle through
the seat to allow a constant bleed-off of a
slight amount of steam during the cycle
to completely eliminate any air pockets
in the cylinder.
• Failure of the trap to operate properly
will result in an uneven distribution of
live steam within the compartment.
Cont,
Cont.
 Typical technical problems
• Below some typical problems in
connection with autoclaves:
 Heating element.
• When the heating elements are
often used with too little or
without water it will burns out
within seconds.
• The heating elements are
covered with lime scale. Then
the heating elements cannot give
off the heat, get overheated and
will also burn out.
 Cont.

• Solid state relays,contactors

• The heating elements are
switched on and off by
electromechanical contactors or in
modern autoclaves by solid state
relays.
Cont.

1.pressure switch
2, contactors
3.timer
4.temprature guage
5,6. relays
7.pressure guage
8. fuse holder
9.low water cut off
10. contactor
11. transformer
 Cont.

 Error code
• In case of a fault, microprocessor controlled autoclaves show
an error code in the display. With the help of the service
manual the fault can be identified easily.
Circuit wiring diagram
Main PCB Ckt
 cont.

 Leaking door gasket

• Rubber gaskets get hard over time and crack.
• A leaking gasket will not necessarily affect the performance
of the autoclave.
• As long as the heating element produces more steam than
escapes through the leakage, the autoclave will work.
• But the escaping steam is of course dangerous for the user and
thus the chamber temprature can not reach .
• Gasket must be exchanged.
• leakage problems can also from loos tubing connections,
heating element connction to the chaber and valves.
 Cont.
• After removing a silicon
gasket it is sometimes
difficult to put it back into
the groove of the lid or door.
• It seems to be too long. Do
not inserting the gasket bit
by bit around the lid but
start with inserting it at the
12 o'clock position, then
continue at 6, 3 and then 9
o'clock.
cont.
 Hot air ovens

• Dry heat can also be used to sterilise products but is less

efficient than the sterilisation with steam.
• The process takes longer and the temperature has to be higher.
• Dry heat is used for the sterilisation of some plastics, papers,
special liquids and powders which cannot be sterilised with
steam.
• One advantage of dry heat is, that it does not cause rusting of
steel products.
• The hot air can be applied without high pressure.
• The standard setting for a hot air oven is:
• 160°C (320°F) for 120 minutes
• 190°C (374°F) for 12 minutes
cont.
 AutoClave Troubleshooting

• Begin: Autoclave. Start the diagnostic process for a work order on an

autoclave
• Does the indicator lamp illuminate?
• Provide appropriate power supply to the autoclave and observe indication
that the device turns on
• Troubleshoot power supply: If the device is connected to power but
does not turn on, there is a problem with the power supply. This could
be a problem with the wiring or connections within the device.
• Is voltage across heating element equal to the expected value?: Use a
multimeter to test the wires leading to the heating element to determine if
it is receiving the expected voltage (wall voltage)
• Troubleshoot control circuitry: If the device is receiving power but
improper voltage is reaching the heating element, there is likely a
problem with the control circuit.
• Ensure that all settings are what they should be for normal autoclave
function
 Cont.

• Does the heating element warm up?: Attach autoclave to power with
lid open and observe whether the heating element begins to get hotter
• Look for rusted or cracked connections: Examine connections
involved with the heating element to determine whether they are
adequate for proper functionality.
• Is the resistance across the heating element less than 20 Ohms?: Use
a multimeter across the heating element to determine its total resistance
• Replace heating element if necessary: If the resistance across the
heating element is greater than 20 Ohms, it needs to be replaced. To
replace the wire within the element, nichrome wire must be used.
• Do temp & pressure gauge needle(s) move?: While autoclave runs
cycle, observe motion of Temp & pressure gauge(s). There must be
displayed values for BOTH parameters to advance from this step
• Does temperature gauge remain at zero?: Determine if value of zero
is given for temperature despite temperature increase
 Cont.

• Does pressure gauge remain at zero?: Determine if value of

zero is given for pressure when pressure is expected to have
increased
• Clean gauge vent: If the gauge works but does not move
during autoclave cycle, then the vent leading to the gauge
input may be blocked. Flush vent with distilled water to
remove blockage.
 Quiz:2
Describe the operation of the autoclave refering to the picture
below.