In order to improve the level of process production safety management and reduce the probability of accidents, a functional safety integrity analysis method for risk prevention and control in the production process was proposed, and verified in conjunction with the steel continuous casting scenario. Firstly, the risk severity of primary accident types was evaluated, and an acceptable risk frequency standard was established. Secondly, the layer of protective analysis was employed to compute the actual occurrence frequency of high-risk accidents, determining whether the addition of new protective measures was necessary. Finally, validation of the safety integrity level of the introduced protective measures was carried out using the Monte Carlo-Markov model. The continuous casting operation area of the converter plant of Daye Special Steel Co., Ltd. was selected as the verification scenario. The results indicate that there are three high-risk accident hazards of molten material explosion, fire, and poisoning and suffocation, and the consequences of personnel casualties in molten material explosion accidents are unacceptable. Therefore, it is necessary to add protective measures with a functional safety integrity level of 2. An explosion protection system was designed with a failure probability of 4.37 × 10^-3, meeting the requirements of functional safety integrity level.