LYONSAFE LTD.

Engineering consultancy and training for safety-critical industries.

Overview

LYONSAFE LTD. is a UK-registered company specialising in high-quality remote safety engineering consultancy and training — with a core focus on functional safety.With a proven track record delivering complex, high-value projects across the oil & gas, air traffic management and defence sectors, LYONSAFE LTD. brings deep domain expertise and a strong understanding of applicable legislation, regulations, and standards — with the ability to identify, interpret, and apply them effectively to meet client needs.With services spanning the fields of system safety, process safety and functional safety, we help safety-critical industries solve complex safety challenges.

Services

Training

LYONSAFE LTD. delivers specialist training across the disciplines of functional safety, system safety and process safety — tailored to each client’s industry, regulatory environment, and team experience level.Training highlights include:

Appointed Capability Lead for Safety Training in the defence sector, with responsibility for the preparation and delivery of internal training on functional safety
Creation and delivery of a full-day introductory course to safety engineering in the air traffic management domain, alongside development of a bespoke corporate Safety Management System (SMS)
Creation of a suite of corporate training modules for the oil & gas industry, covering Introduction to Functional Safety, Safety Integrity Level (SIL) Assessment and SIL Verification
Remote training delivery to clients in the UK and Japan, covering:

Safety Engineering Fundamentals (hazards, risk, risk tolerability, risk reduction)
Def Stan 00-056 and 00-055
IEC 61508
ARP4761

Consultancy

LYONSAFE LTD. provides technical consultancy across a range of safety and reliability disciplines, drawing on extensive experience in regulated, safety-critical industries.Key service areas include:

Independent Safety Assessor (ISA) and Auditing

Independent third-party compliance assessments, as required by standards such as IEC 61508 and IEC 61511
Full auditing of your project or corporate Safety Management System, with clear, actionable follow-up recommendations
Familiarity with tools such as Conformity Assessment of Safety-related Systems (CASS) Targets of Evaluation (ToEs) and frameworks such as Project-Oriented Safety Management System (POSMS) used in UK defence and regulated industries

Safety Management Systems

Preparation of full corporate SMS in the air traffic management industry (including policy, processes, procedures, guidance, tools, forms, records and training)
Development of functional safety elements of the corporate SMS in the oil & gas sector, including guidance, procedures, calibrated risk graph and LOPA tools, forms and training
Contributions to SMS evolution and training materials in the defence sector

Safety Planning

Creation and revision of Safety Management Plans and Safety Philosophies, with reference to project documentation and applicable legislation, regulations and standards
Use of tools like MindManager to plan safety engineering activities, deliverables, review milestones and path to compliance

Hazard and Failure Mode Identification

Strong expertise in HAZID, HAZOP, FHA, ZHA, SWIFT, FMEA, FMECA and FMEDA techniques
Involvement from early career (scribing studies and managing HAZOP and SIL assessment actions) to leading studies and hazard workshops
Skilled in maintaining hazard logs and safety requirement registers

Risk Assessment and Safety Analysis

Delivery of both quantitative and qualitative risk assessments, tailored to project needs and aligned with relevant standards and regulatory expectations
Expertise in industry-recognised techniques including Bow-Tie Analysis, calibrated risk graphs, Layer of Protection Analysis (LOPA), and ALARP demonstration and justification.
Extensive experience with Fault Tree Analysis (FTA) and Event Tree Analysis (ETA), including use of advanced tools such as Isograph for complex safety integrity and reliability modelling

Functional Safety

Deep understanding of IEC 61508 and IEC 61511, and knowledge of similar standards such as ISO 13849 and ISO 26262
Functional Safety Management planning and gap analysis
Production of detailed Safety Requirement Specifications (SRSs)
Safety Integrity Level (SIL) assessment using calibrated risk graphs and Layer of Protection Analysis (LOPA)
Documentation of detailed safety function architectures using electrical schematics and functional block diagrams, completion of Failure Modes, Effects and Diagnostic Analysis (FMEDA)
Review of Software Management Plans in line with IEC 61508 Part 3
SIL verification activities, including:

Quantification of random hardware failures using fault trees and Reliability Block Diagrams (RBDs)
Evaluation of hardware architectural constraints using Hardware Fault Tolerance (HFT) and Safe Failure Fraction (SFF)
Assessment of systematic capability

Reliability Engineering

Developed fault tree and RBD logical models to represent complex systems
Reliability data gathering and use of specialist software (Isograph, PTC Windchill)

Systems Engineering

Structured systems engineering support across the full lifecycle, aligned with ISO/IEC/IEEE 15288 and best practice
Requirements derivation, decomposition and management
Lifecycle-aligned verification and validation planning
Integration of systems engineering with system safety activities

STAMP/STPA

Practical understanding of Systems-Theoretic Accident Model and Processes (STAMP) and application of Systems-Theoretic Process Analysis (STPA)
Supported clients to adopt a systems-thinking safety approach, where safety is managed as a dynamic control problem
Provided practical guidance to integrate STAMP/STPA methods alongside traditional functional safety practices

Meet the founder

Ben Lyons MSc (Eng) FS Eng (TÜV Rheinland) MSaRS
Founder and Principal Consultant

Ben is a safety engineer with over 12 years of experience supporting and leading complex engineering projects across the oil & gas, air traffic management and defense sectors. He is the founder and principal consultant at LYONSAFE LTD., where he provides high-quality consultancy and training in functional safety, system safety, process safety and reliability engineering.He holds a BSc (Hons) in Mathematics and an MSc (Eng) in Process Safety and Loss Prevention, awarded with distinction. His dissertation — comparing safety engineering principles and techniques across different industries — received the university prize. Ben is also a TÜV Rheinland Certified Functional Safety Engineer and a Member of the Safety and Reliability Society (MSaRS).His experience spans safety management and the analysis and realisation phases of the safety lifecycle — including Safety Management System (SMS) development, safety planning, hazard identification, risk assessment, safety requirement management, safety analysis and safety case authorship. He has a deep understanding of IEC 61508 and related standards such as IEC 61511, developed through years of hands-on project experience — including the practical, often complex nuances of applying these frameworks in dynamic, safety-critical environments.With a strong background in both process safety and system safety disciplines, and working knowledge of diverse regulations and standards, Ben is well positioned to support clients across a broad range of safety-critical industries, including aerospace, automotive, nuclear and rail. His adaptable, standards-driven approach enables him to identify and apply the right frameworks to meet each client's technical and regulatory needs.