Shell Long Beach HDV Hydrogen Refueling Station

FASTECH Builds a Shell HDV Hydrogen Refueling Station in Long Beach, CA

Long Beach, CA
FASTECH constructed the second of three Shell HDV hydrogen refueling stations as part of the “Shore to Store” zero-emission trucking infrastructure program.
Backed By Major Stakeholders
The project was supported by the California Air Resources Board (CARB), Port of Long Beach, Toyota, and major trucking companies.
Groundbreaking Technology
Hydrogen for the Long Beach site will soon be generated using state-of-the-art fuel cell energy technology at the adjacent tri-generation power plant being constructed by FASTECH.
Key Hydrogen Infrastructure Hub
As one of the port’s first major investments in zero-emission hydrogen trucking infrastructure, the Shell HDV hydrogen refueling station is becoming a proving ground for reducing emissions in and around the port.


FASTECH previously partnered with Shell to construct light-duty vehicle (LDV) hydrogen refueling stations in Northern California as part of Shell’s Trident program in 2018 and 2019.

The Project

The Shell HDV hydrogen refueling station in Long Beach was the second of three planned HDV refueling stations (the others in Wilmington and Ontario, California) constructed by FASTECH as part of the “Shore to Store” zero-emission trucking infrastructure program.

To accommodate larger vehicles like Class 8 trucks and additional daily fills for smaller passenger vehicles, these heavy-duty vehicle (HDV) sites were designed for higher on-site storage capacity and faster fueling times than their LDV predecessors.

In order to facilitate round-trip trucking from the port to inland destinations, it was imperative to complete all three projects in close succession. The Long Beach project broke ground three months into the Ontario project and two months before starting the Wilmington project. At one point, FASTECH was working on all three Shell HDV sites simultaneously.

In addition to the three Shell HDV hydrogen refueling stations, FASTECH also constructed an LDV hydrogen refueling station right next door to the Long Beach HDV site. To connect the neighboring LDV and HDV stations, FASTECH installed 1,200 feet of special stainless steel piping, pipe coating, and cathodic protection.

The Process

Throughout the project, FASTECH encountered various challenges and successfully worked with its partners to find solutions while minimizing the impact on the project schedule and budget.

Equipment Coordination. The Long Beach HDV site, along with its companion sites in Wilmington and Ontario, used NEL’s latest compressors and dispensers in conjunction with Tenaris high-pressure ground storage vessels. Since the equipment and storage vessels were coming directly from Europe, FASTECH had to make ongoing adjustments to the construction schedule to accommodate changes in delivery dates.

Environmental Conditions. The site posed several challenges, including high groundwater levels and areas of contaminated soil. The on-site storage bottles weighed more than 500,000 pounds when fully assembled and required the use of drilled piers. These piers were drilled to a depth of more than 18 feet below grade by applying techniques such as drilling fluid and concrete tremie pipes to place concrete underwater. Contaminated soil was classified and sequestered on-site based on real-time sampling and testing, and was subsequently hauled away to special facilities for proper disposal.

Project Integration. Special care was taken to ensure the future success and integration of the station with the port, the LDV hydrogen refueling station, and the future FuelCell Energy tri-generation power plant. The locations of all improvements were evaluated to ensure that the site would not impede future port roads and rail lines. The site was also “future-proofed” by installing foundations and underground utilities for additional equipment to receive and process the hydrogen gas produced at the upcoming tri-generation power plant.

How Long Did the Project Take?

The project broke ground in March of 2020 and was substantially complete by July of 2020. Commissioning was finished in August of 2020, with the station open to the public by October of 2020.

As construction finished ahead of the electrical and internet utilities, FASTECH helped implement temporary generators and wireless communication technology to keep the project moving through commissioning.

The Results

The Shell HDV Hydrogen Refueling station in Long Beach is becoming a key hub for hydrogen infrastructure. It supplies hydrogen fuel to the smaller LDV refueling station located next door on the Toyota Logistics Services property (built by FASTECH in 2021), and will soon receive hydrogen gas directly from the adjacent FuelCell Energy Tri-Generation Plant, currently being built by FASTECH.

The connection between the Long Beach HDV site and the new FuelCell Energy plant is a breakthrough for hydrogen supply logistics. By creating a steady supply of hydrogen from an on-site generation facility, the need for truck-supplied hydrogen is greatly reduced or eliminated, station uptime is increased, and a more reliable source of hydrogen is made available for customers.

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 EPC partner for your hydrogen, CNG, or LNG fueling 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 engineering 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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