When permit assumptions collide with operational reality
Freeport LNG expanded its leak detection and repair (LDAR) capabilities during construction and early operations at a pretreatment and liquefaction plant permitted separately under Texas Commission on Environmental Quality (TCEQ) new source review permits. Permits were issued years ahead of final design and construction, which meant emissions limits and monitoring requirements reflected early assumptions rather than the facility as built.
As startup approached, that disconnect became operational. The leak detection and repair (LDAR) approach assumed during permitting would not deliver the emissions control or field efficiency required once units were live. Closing the gap had to happen without slowing production or weakening regulator or community trust.
Onterris was engaged to develop and implement a site-ready LDAR program that matched operating reality while staying aligned with permit requirements and stakeholder expectations.
Building an LDAR program for operating reality
Initial permit assumptions were based on an estimated component count of approximately 10,000. By conducting a comprehensive inventory review, Onterris identified more than 76,000 components that required monitoring across the facility.
At that scale, their initial LDAR plan, using Method 21, was not operationally feasible. Working with the Freeport LNG team, Onterris developed a different LDAR strategy, one the site could realistically execute while still achieving the emissions reduction required for compliance and reducing long-term risk.
Introducing OGI as a practical alternative
Onterris worked with Freeport LNG and regulators to implement an OGI program under an approved alternative work practice (AWP). Although the permits were already in place, Onterris supported the operator in developing a clear technical and operational case, showing how the approach would meet or exceed existing LDAR requirements.
By working directly with regulators, we proved the AWP program could run at scale across a complex, interconnected facility, bringing a superior leak detection technology that efficiently delivers measurable emissions reductions. This isn’t just about meeting today’s permit benchmarks. It’s about positioning operations for the regulatory landscape of tomorrow. The name of the game is finding emissions faster, and AWP is built for exactly that.
Faster detection, broader coverage, better decisions
With OGI in place, survey teams now screen far more components per hour, enabling bi-monthly facility-wide scans instead of quarterly inspections. Leaks are identified and confirmed faster, reducing misidentification, repeat work, and delays in repair. The program has also delivered safety and operational benefits. Previously unmonitored or hard-to-access leaks are identified earlier, findings feed directly into maintenance and safety workflows, and reduced product loss provides ongoing operational value.
Hands-on program management at scale
Three full-time Onterris professionals manage the LDAR program on site, overseeing monitoring, quality assurance, repair tracking and complex emission calculations. Facility-wide camera surveys are conducted every two months alongside annual requirements and ongoing repair verification.
LDAR program management software is fully integrated into their operator workflow, supporting rapid response, transparent reporting and consistent compliance documentation.
Operational reality meets lasting compliance
At Freeport LNG, the turning point was aligning the LDAR program with the operational reality. The site now runs a long-term, site-ready program with stronger emissions control, predictable execution and audit-ready documentation, creating a model the team can carry forward as the facility ramps and matures.
