Karim Segond, Consulting Engineer for Ventilation and Cooling

Karim Segond

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Karim Segond was born in 1973 in Toulouse, France. After obtaining the high school diploma (baccalauréat scientifique), he began studying mechanical engineering at university in Toulouse. In 1996, he left the region in order to continue his studies at the Technical University of Berlin where he obtained the Master in Mechanical Engineering in 2000. During his studies, Karim worked at Siemens Large Drives in Berlin, where his main tasks were the 3D thermal and flow calculations for a synchronous motor with turbo rotor. He was supervised by Mr. Zwarg.

Steam turbines and power plants for Alstom in Switzerland

After his studies, Karim moved to the German-speaking part of Switzerland in order to work at Alstom Power in Baden. The company was formerly called ABB Kraftwerke and is now part of General Electrics.
Together with other aerodynamicists, mechanics and designers, he worked on the development of new low-pressure steam turbines. He used the company's own CFD programs with Euler or Navier-Stockes solver to quickly perform parameter variations for the last turbine stages. He also improved the design process using the 6sigma method. The toughest challenge of his carrier was certainly the wet steam calculations for a low-pressure steam turbine. …
He shortly left Alstom in 2006 for the small engineering consulting company Air Flow Consulting in Zurich. He simulated the smoke extraction for fire safety, the air conditioning and the air guide for clean rooms. He used ICEM and Harpoon for the mesh generation and CFX as a CFD solver.

In 2007 he moved back to Alstom power, this time for plant construction, where he worked in the office in Baden as well as on combined cycle power plant construction sites in England. He gained experience in the fields of management, tendering as well as commissioning and operation of the combined cycle power plant.

Self-employed as a calculation and consulting engineer at e-cooling

Since 2011 Karim has been working as a freelance consulting engineer for cooling calculations of electrical equipment like Electrical Machines, Power Electronics, and Electronics. He mostly works from his office in Berlin but he can also work at the customer’s. His first task was performing 3D thermal and flow calculations for an electrical motor as an external contractor at ABB Minerals in Switzerland. It was a slow rotating pole salient synchronous ring motor; the calculations were performed with the CFD pre- and post-processor and solver CFX in combination with Ansys Meshing and Ansys Design Modeler.

After this task, he benchmarked the different CFD tools and he clearly preferred to work with software based on a cartesian mesh like FloEFD, FloTHERM, or Solidworks Flow Simulation. These tools allow to set up easy and fast heat transfer cases; the resulting costs are correspondingly low. By using these tools Mr. Segond offers a distinct competitive advantage to his customers over the ones still using older tools.

Besides the electrical machines, Karim is investigating the thermal management of the power electronics components used to drive such large engines. Here CFD can be leveraged to optimize the design and ensure the best possible cooling for the components. He has also turned his attention to the overall cooling of a system: such cooling systems are too big and too complex to simulate with 3D CFD software. Therefore it is necessary to analyze them using a thermal and fluid flow network that is modeled in a 1D CFD-tool such as FloMASTER. This combined solution enables Karim to provide the qualities of both tools and provide the ultimate cooling solution to his customers.  


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