ESR is known as an alternative step on the continuous improvement in single ingot production for heavyforgings. In the recent past a new state of the art ESR remelting system was installed with the possibility toproduce ingots in diameter from 1000mm for 45tons till 2000mm for 145tons. Consumable electrodes fromtraditional fabrication processes which consist of melting with electrical arc furnace, refining, degassingof the steel and bottom pouring will be used to produce one single heavy ingot with best cleanness withthe help of electrode exchange technique. This paper tells about the furnace characteristics and the efforts tobe made to ensure high quality level in material and furnace preparation as well as save automatic productionperformances during remelting and electrode exchange. Finally the results of ingots characterized by anelevated level of chemical homogeneity and internal quality such as to ensure the absence of defectgreater than 0.5mm AVG during the final inspection of the forged part from the ESR production will bepresented. The ESR process serves for the reproducible quality in heavy ingot making and tightens the limits inspecifications together with high material yield
