As the world's largest supplier of renewable geothermal energy, Calpine Corp. knows a thing or two about efficiency. And when the company opened a new power plant in Decatur, Ala., it sought efficiency in a space-saving storage system consisting of modular storage units, a mezzanine and cabinets for repair parts for its equipment.

The Calpine Morgan Energy Center installed a customized storage wall and mezzanine system to store a wide array of items from small nuts and bolts to large parts for steam and gas turbines. The storage unit's mix of modular components such as drawers, roll-out trays and wide-span beams provides maximum storage capacity of various sized parts. Its effective use of vertical space also enables a smaller footprint than traditional shelving and cabinets.

This self-enclosed storage area is created by four rows of storage wall sections, all facing inward, with two aisles. Arranged back-to-back, the interior wall sections feature open double-deep shelving for storing long items such as equipment shafts. The outer wall sections consist of traditional 4-foot wide shelving. Lockable wire doors secure the storage area while a double-door opening is used for dispensing parts to workers.

A variety of regularly used parts are stored in 4 × 2 foot drawers inside the storage area. Each customized drawer holds 20 different parts ranging in size and shape. They extend 100% for easy viewing of all contents. Partitioning slots on all sides of the drawers allow workers to configure the drawers to suit their needs and fully utilize cubic capacity.

"The drawer's custom-configured interiors provide safe, accessible storage for every individual part," says Rodney Looney, director of purchasing and warehousing. "Now parts can be easily located and scanned, which has allowed the plant to streamline its inventory."

In addition, the plant's instrument and electrical shop technicians utilize electrostatic dissipative (ESD) cabinets to safely store an array of parts and tools. Coated with ESD paint, the cabinets create a dust-free environment ideal for protecting sensitive electronic equipment.

Bulk items and less frequently needed parts are stored in the mezzanine area situated directly above the storage wall units. A custom cage with sliding doors surrounds the upper mezzanine level to protect employees while allowing forklift access.

"The versatility and durability of the storage wall and mezzanine system is just what Calpine was looking for," says Looney.