Hands-free completion system eliminates red zone exposure in upper completions

Mechanizing upper completion tasks can eliminate personnel exposure in the red zone entirely, turning a historically manual, high-risk process into a safer and more consistent operation, said Neil Alleman of Expro. Speaking to DC in this video from the 2026 IADC Advanced Rig Technology Conference in Austin, Texas, on 25 August, Mr Alleman discussed the risks associated with conventional upper completion setups, particularly how manual operations require multiple people in the red zone to accomplish an assortment of tasks (manipulating control lines, installing a hole cover, installing a control line clamp).

Mr Alleman, Completion Handling Product Line Manager at Expro, also outlined the company’s hands-free upper completion system, which uses mechanized solutions – including a remote manipulator for control line handling and automated hole cover placement – to reduce red zone exposure for each task. He noted that the full system has cut total red zone exposure from 16 man-minutes per clamp install to zero, while also removing the operational variability that comes with manual, personnel-dependent work.