SOP for Operation and Cleaning of Steam Sterilizer

1.0 PURPOSE

To lay down the procedure for Operation and Cleaning of Steam Sterilizer (Autoclave).

2.0 SCOPE

This is applicable to double door Steam Sterilizer present in Microbiology.

3.0 RESPONSIBILITY

Trained Quality Control Microbiologist or Trained Operator is responsible for operation and cleaning of Steam Sterilizer as per procedure.

4.0 ACCOUNTABILITY

Head of Department

5.0 PROCEDURE

5.1 Checks before starting of equipment

5.1.1 Check the validation status before using the equipment.
5.1.2 Check all utilities such as compressed air, water are connected as per the requirements.
5.1.3 Check the cleaning status of the equipment.
5.1.4 Check the water level in the boiler of the Autoclave. It should be according to the mark.
5.1.5 Put the autoclave tape on each item.
5.1.6 Mention the run number and sterilization date on tape.

5.2 Operating Procedure

5.2.1 Put ‘ON’ the electric mains.
5.2.2 Keep main supply switch in ‘ON’ position.
5.2.3 Put control switch in ‘ON’ position.
5.2.4 Keep emergency stop button in ‘Released’ position.
5.2.5 Put Auto-Off-Manual switch in ‘Manual mode’.
5.2.6 Operate ‘Lamp Check Test’ to check the functioning status of indicators “ All indicators shall glow”.
5.2.7 Open the door from the non-aseptic side by pressing door open button.
5.2.8 Prepare the required materials and pack the materials in sterilization reels for laboratory glassware and accessories, in Dacron bags for garments and with cotton plugs or caps as appropriate for media containers.
5.2.9 Label each pack of laboratory glassware, accessories and garments with a strip of chemical indicator tape and write the date of sterilization and use before date. For media containers label as per SOP for media preparation.
5.2.10 Put the required material on the shelves of the chamber as per validated load patterns and quantity loaded should conform between the minimum and maximum validated load patterns. When the load is in between the minimum and maximum load patterns, load as per maximum load pattern. Enter the load details in appropriate annexures.
5.2.11 Place chemical indicator on at least one of the article to be sterilized / or in sterilization pouch, for every cycle other than Bowie-dick and Vacuum leak test.
5.2.12 Close the door by pressing the close button.
5.2.13 Put Auto-Off-Manual key switch in Auto mode.
5.2.14 Switch on the dot-matrix printer and strip chart recorder and ensure the papers are properly loaded.
5.2.15 Enter the cycle details, run number; load details and sterilization hold times in the Autoclave Log Sheet and appropriate Autoclave Load Details format. The run number shall be allotted to each cycle starting from 01 every day.
5.2.16 Select the desired set parameters that are fed in Programmable Logical Control (PLC) as per validation summary report and run the cycle.
5.2.17 After completion of the cycle, unlock the key. Open the door from the aseptic side by pressing “Door Open’ button.
5.2.18 Remove the load from the shelves.
5.2.19 Close the door by pressing “Door Close’ button and lock the key.
5.2.20 Post sterilization, write the run number on the chemical indicator, sign and attach to Autoclave Load Details reporting format.

5.3 Operation of Programmable Logical Control (PLC)

5.3.1 Press F4 Key in the PLC keypad, “Menu 1’ will appear, with following options:
• F1 – Set/View Parameter: For Setting and Viewing Cycle Parameters.
• F2 – Login Password: To Login to PLC.
• F3 – Menu 2: For Going to Next Menu.
• F4 – Menu 1: To Return To Previous Menu.
5.3.2 Press F3 Key in PLC Keypad, “Menu 2” will appear with following options:
• F2 – Process Data: Shows real-time readings of all sensors.
• F2 – Start Process: To select, print and start the required cycle.
• F3 – Batch Data: To enter batch details
• F4 – Main menu: To return the previous menu
5.3.3 In ‘Menu 2’ press F3 to go to ‘Batch Data’ and enter the Sterilizer No, Load No and Operator Code and return to the previous menu.
5.3.4 In ‘Menu 2’ press F2 to Key to go to ‘Start Process’ Menu with options:
• F1 – Start: to start the process.
• F2 – Off Print: To print the cycle parameters
• F3 – To Select the required Cycle
• F4 –To return to the previous menu.
5.3.5 From ‘Menu 2”, select the required cycle, print the cycle parameters and start the process by pressing appropriate keys in ‘Start Process’ Menu and its submenus.

5.4 Vacuum Leak Test (VLT)

5.5.1 Perform the Vacuum Leak Test as the first cycle of the day before any other cycle in the autoclave in cold conditions.
5.5.2 Operate the cycle as per 5.2 by selecting process “Vacuum Leak Test (VLT)”.
5.5.3 At the end of the cycle verify the cycle printouts for a vacuum leak and it should be not more than 0.013 bar.

5.5 Bowie-Dick Test (B&D)

5.5.1 Bowie-Dick Test should be performed once every week after completion of Vacuum Leak Test.
5.5.2 Place the Bowie-Dick Test pack in the autoclave and operate the cycle as per 5.2 by selecting process “Bowie-Dick Test (B & D)”.
5.5.3 At the end of the cycle remove the test pack from the autoclave and observe for color change. The Bowie-Dick pack indicator should turn from blue to black.

5.6 High-Pressure High Vacuum (HPHV) Process

5.6.1 HPHV cycle should be operated after completion of Vacuum Leak Test and Bowie-Dick Test (Whenever Applicable) and this cycle is used for sterilization of porous materials.
5.6.2 Place the load as per load configuration and operate the cycle as per 5.2 by selecting appropriate process based on the type of load to be sterilized as per the following table:

Load	Process
Filtration Accessories	HPHV 1
Disinfectant and Sampling Accessories
Glassware and Air Sampling Accessories
Garments	HPHV 2

5.6.3 At the end of the cycle unload the material from the sterile side.

5.7 Standard (STD) Process

5.7.1 Standard cycle should be operated after completion of Vacuum Leak Test and Bowie-Dick Test (Whenever Applicable) and this cycle is used for sterilization of culture media and diluents.
5.7.2 Place the load as per load configuration and operate the cycle as per 5.2 by selecting ‘Standard Process’.

5.8 Sterilization and Replacement of Air In-Line Filter

5.8.1 Air In-Line Filter should be with a sterilized once in every two weeks.
5.8.2 Sterilization: Pack the filter in sterilization reels and place in an autoclave and sterilize using HPHV1 Process.
5.8.3 Replacement: Open the stainless steel filter housing and remove the filter and replace with a previously sterilized filter.
5.8.4 Integrity Test: Perform Integrity test/bubble point test of filters before replacement and after removal from the housing. It should confirm the specifications as per manufacturer’s instructions.
5.8.5 Sterilization of filters should not exceed the number of cycles mentioned in the filter manufacturer’s CoA.

5.9 Alarms acknowledgment procedure

5.9.1 When an alarm occurs, press F4 key for the main menu, then press F3 key for Menu 2.
5.9.2 Press F1 key for process data, press the down arrow ▼ key to scroll the screen.
5.9.3 F1 (Alarm screen) and F4 (Main screen) will appear on the screen.
5.9.4 Press F1 (Alarm screen) then press the down arrow ▼ key to scroll the screen.
5.9.5 F1 (Acknowledge) and F4 (Process data) will appear on the screen.
5.9.6 Press the F1 key to acknowledge the alarm.

5.10 Strip Chart Recording and Reading

5.10.1 When printing the cycle parameters through PLC, simultaneously start the strip chart by pressing ‘Function” button once and ‘Enter’ Button twice. This will print the current values of all sensors.
5.10.2 To start recording of cycle on strip chart, press ‘Red’ Button when the autoclave cycle starts and after completion of cycle again ‘Red’ Button to stop recording.
5.10.3 The Strip Chart should be read horizontally for time and vertically for values. Settings of the Strip Chart as follows:
• Chart Speed – 60 mm/hour.
• Horizontally 1 mm equals to 1 min.
• Vertically 1 mm equals to 2°C
5.10.4 Pictorial depiction of Strip Chart:
5.10.5 Sensors and their details are as follows:

Probe No	Colour	Placement	Parameter
1	Violet	Right Hand Sterile Side	Temperature
2	Red	Right Hand Front Side	Temperature
3	Green	Left Hand Front Side	Temperature
4	Blue	Left Hand Sterile Side	Temperature
5	Brown	Drain	Temperature
6	Black	Drain	Pressure

5.11 Cleaning Procedure

5.11.1 Clean the steam sterilizer external stainless steel surface with a cleaning agent with a clean cloth.
5.11.2 Clean the chamber drain.
5.11.3 Clean the chamber with 2% v/v soap solution and thereafter with purified water
5.11.4 Frequency: Cleaning once a week or when there is spillage.

5.12 Shut-down procedure

5.12.1 Clean the autoclave before shutdown if there is any spillage.
5.12.2 After completion of the work:
• Keep ‘control ON’ switch in OFF position.
• Keep ‘heater ON’ switch in OFF position
• Keep AUTO-OFF-MANUAL switch in OFF position.
• Keep the main switch in OFF position

5.13 Autoclave load pattern

5.13.1 For autoclave load pattern details, refer the validation document.

6.0 ABBREVIATIONS

SOP - Standard Operating Procedure
SLV - Solenoid valve
STD - Standard
PLC - Programmable logical control
HPHV - High-pressure high vacuum
VLT - Vacuum leak test
B&D - Bowie Dick test

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