Case Study

FASTECH Installs 7th Hydrogen Refueling Station for Shell

San Jose, California: FASTECH partnered with Nel Hydrogen to build a hydrogen refueling station for Shell Renewables and Energy Solutions in San Jose, California.
Implemented Safety Protocols & Stayed On Budget: FASTECH successfully implemented appropriate safety protocols for the on-site team and worked with key vendors to avoid the impacts of ever-increasing material lead times and costs.
Finished During Covid-19 Restrictions: The San Jose hydrogen fueling station project was the fifth Shell hydrogen station that FASTECH completed since COVID-19 restrictions went into effect.
Met Project Completion Goals: Finished the project on time and with no recordable safety incidents.

The Project

Due to permitting challenges with the city of San Jose, Shell’s hydrogen refueling station project start date was significantly delayed. As a result, Shell reached out to FASTECH to complete San Jose as the seventh and final project of their Trident program, which included hydrogen installations in Fair Oaks, Citrus Heights, San Francisco, and Berkeley, CA. Shell needed FASTECH to mobilize as soon as the city approved the project and complete it as quickly and safely as possible.

In the middle of the project, delivery of major equipment was delayed, requiring FASTECH to change gears to accommodate the new schedule. FASTECH continued to work on other tasks to minimize the overall impact of delays to the project.

The Process

FASTECH started the project by identifying the key site-specific challenges that would need to be addressed during construction. These items were incorporated into a proven critical path schedule and executed by FASTECH’s on-site construction team.

FASTECH installed equipment supplied by Nel Hydrogen, similar to what was installed on Shell’s other Trident sites. FASTECH’s experience installing Nel’s equipment on previous projects was a key contributor to the project’s success.

FASTECH also proposed modifications to a steel trellis structure originally designed to be installed over the top of the major equipment compound. FASTECH worked directly with the City to change the design and keep the same architectural appearance from the outside while removing many of the trellis “rafters” across the top of the equipment. This step saved on construction costs and allowed for easier maintenance of significant equipment elements.

FASTECH followed a typical schedule sequence:

Cleared the site and grade for new slabs and utilities
Installed all new underground utilities
Poured the primary equipment slabs
Set major equipment
Completed all aboveground utility connections
Completed all finishing architectural elements

Other site-specific tasks related to installing a new hydrogen station were incorporated into the overall schedule and completed in parallel with the critical path.

How Long Did the Project Take?

Construction began in early February and was completed in early June 2021.

Construction Start ... Feb 2021
Construction Finished ... Jun 2021

The Results

The project finished within the originally projected schedule, with equipment delivery delays offset by the acceleration of other tasks.
The San Jose station is a much-needed addition to Shell and California’s hydrogen refueling network.
Fun fact: FASTECH’s on-site team noted that customers in hydrogen fuel cell vehicles began stopping by the site regularly, even before construction was completed, to inquire about the station’s grand opening date.

FASTECH: Your Alternative Energy Solutions Partner

Whether you’re already committed to selling alternative fuel or planning to transition in the future, choosing the right construction partner for your hydrogen, CNG, or LNG fuel station is a significant business decision.

At FASTECH, we have over two decades of experience in the energy industry. We specialize in end-to-end solutions, from planning and construction to ongoing maintenance and testing for many types of alternative fuel, including hydrogen, CNG, LNG, and propane. To date, we’ve built more hydrogen stations in California than anyone else.

To start designing your renewable energy infrastructure project, contact us today.

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