Critical Safety Considerations For Autoclaves

Autoclaves, defined as pressurized vessels, are used in various sectors for different purposes. They are employed in various processes where products are placed directly into the autoclave or into a chamber, exposed to pressures higher than atmospheric pressures, and in most cases, subjected to high temperatures. Regardless of the intended use, there are crucial aspects that must be carefully observed in all autoclaves, as autoclaves are high-risk equipment.

The most serious risks arise from the uncontrolled release of energy within the autoclave when critical components fail from a safety perspective. This situation can lead to the violentejection of autoclave components and/or materials within theautoclave. In addition, a range of potential risks is associatedwith operating an autoclave, such as steam burns, scaldingwith hot liquids, and hand and arm injuries when closing theautoclave door.

In order to prevent physical injuries, anyone using an autoclave must be aware of potential hazards and necessarysafety measures. By taking appropriate safety precautions, theabove-mentioned risks can be mitigated. The precautions to be taken depend on the size of the autoclave, operating pressure, and the type of pressurizing medium. However, in a general sense, critical safety points are common to all autoclaves.

Fundamentally, attention should be paid to the followingcritical points:

Personal Protective Equipment (PPE):

Appropriate protective equipment should be worn. For safety purposes, eye and face protection (a face shield minimizes facial risks).

Heat-resistant gloves should be used during loading and unloading of the autoclave. Long-sleeved clothing should be worn to protect wrists and forearms

Training:

Training is absolutely necessary before using the autoclave. The training and instructions provided to operators should cover all the procedures and information they need to operate the system safely. Additionally, it should include special procedures to be followed in case of an emergency. Training not only minimizes the risk of harm to personnel, but also ensures the achievement of the intended outcome with the process.

Applying Pressure Accidentally with a Person Inside the Autoclave:

Ideally, autoclaves should have a 'man inside' alarm. Even if such an alarm is present, personnel should press the emergency button and take the control panel key with them before entering the autoclave. This ensures that there is no risk of the equipment being activated while personnel are inside.

Control of Automatic and Manual Systems:

The control of an autoclave can be entirely manual, but programmable electronic systems are becoming increasingly common in autoclave control. The monitoring and control capabilities provided by these systems can be highly complex. With automatic systems, the detection of a malfunction can be observed, and automatic shutdown and remote monitoring can be implemented.

In automatic autoclave systems, it is necessary to configure all safety devices in such a way that, in a hazardous situation, the autoclave's energy (i.e., the pressurizing medium inside the autoclave) is safely dissipated. These hazardous situations include:

• Power Loss
• Pressure Loss
• Overpressure
• Overtemperature
• Emergency Stop Activation
• Locking/Sensor Mismatch

Accidental Opening/Failure of the Lid Mechanism Under Pressure:

The closure of the autoclave door should be ensured using automation systems and related switches. Pressurization should not be carried out until it is confirmed that the door is fully closed.

The autoclave cannot be pressurized unless the door is completely closed, the safety mechanism is fully engaged, and the autoclave is made airtight. This is typically achieved by interlocking between the door safety mechanism and the pressurization system.

As part of any automatic door-opening system, door position monitoring should be verified. This can be achieved by installing multiple position sensors. Adding a visual indicatoris also recommended to allow the operator to physically check the door's position.

Preventive Maintenance:

To ensure the safety of autoclaves, there should be an appropriate monitoring plan in place to keep all critical components in efficient working order. This plan should include daily, weekly, and annual checks performed by trained operators to ensure that all critical safety devices are functioning effectively. Among these, the importance of annual periodic maintenance is significant and deserves emphasis. Systematic and periodic checks of equipment for potential workmanship errors are essential for safety. Additionally, the equipment body should be inspected for corrosion, and the gears in the door should undergo non-destructive testing, both of which should be regularly checked each year. Preventive maintenance will greatly enhance the efficiency of your autoclave, reduce downtime, and save costs on expensive repairs. Small adjustments or repairs made through preventive maintenance can be seen as a planned examination that prevents major repairs or early replacement of parts. Ensuring safety and delaying or preventing an emergency situation makes preventive maintenance critically important.

In conclusion, autoclaves are high-risk equipment. Therefore, minimizing the risk is of great importance for companies both financially and morally. By considering the safety elements described above and incorporating them into a company culture, choosing a reliable company with a long-standing experience in the industry, and supported by significant references, will minimize the associated risks.