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Energy Conversion and Management 48 (2007) 3146–3153

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Modeling and dynamic control simulation of unitary

gas engine heat pump
Yang Zhao *, Zhao Haibo, Fang Zheng
Department of Thermal Energy Engineering, Tianjin University, Tianjin 300072, PR China

Received 1 September 2005; received in revised form 6 July 2006; accepted 30 January 2007
Available online 14 September 2007

Abstract

Based on the dynamic model of the gas engine heat pump (GEHP) system, an intelligent control simulation is presented to research
the dynamic characteristics of the system in the heating operation. The GEHP system simulation model consists of eight models for its
components including a natural gas engine, a compressor, a condenser, an expansion valve, an evaporator, a cylinder jacket heat exchan-
ger, an exhaust gas heat exchanger and an auxiliary heater. The intelligent control model is composed of the prediction controller model
and the combined controller model. The Runge–Kutta Fehlberg fourth–fifth order algorithms are used to solve the differential equations.
The results show that the model is very effective in analyzing the effects of the control system, and the steady state accuracy of the intel-
ligent control scheme is higher than that of the fuzzy controller.
 2007 Elsevier Ltd. All rights reserved.

Keywords: Gas engine heat pumps; Dynamic simulation

1. Introduction researchers have to adopt the existing research findings of

The last few years have seen a growing interest in the use
of the combined cycle system of the heat pump driven by a
natural gas fueled engine. This is partially due to its energy
saving achieved by using a high performance natural gas
engine to drive the compressor with an efficient reverse
cycle. Its high efficiency results from the heat recovery from
the engine exhaust gas and cylinder cooling and capacity
modulation. The capacity modulation can be made by reg-
ulating the gas engine rotation speed to meet the air condi-
tioning load. The system has become one of the available
schemes of the cooling and heating combination (CHC)
for environmentally friendly buildings [1].
Optimal control for the natural gas engine heat pump
can reduce the energy consumption effectively, but up to
now, few professional studies have been made on it so that
*
Corresponding author. Tel.: +86 22 27890627; fax: +86 22 27404625.
E-mail address: Zhaoyang@tju.edu.cn (Y. Zhao).
the heating and air conditioning system, which makes it
impossible to know the exact variations of the parameters
of the system entirely [2,3].
Among the many control methods for heat pumps and
other heating and air conditioning systems, the PID (pro-
portional-integral-derivative) algorithm is very common.
Its performance is satisfactory in most cases, but the PID
algorithm cannot produce satisfactory results because of
the peculiarities in the operation of heat pumps. For exam-
ple, some components in heat pumps have highly nonlinear
operating characteristics, and some control loops have time
varying transport delays. Moreover, for many systems, the
exact models are poorly understood. Even if the exact mod-
els could be derived, the PID algorithm still has problems
such as over controlling. Many researchers have attempted
to make improvements to the PID algorithm or find new
methods for heat pumps control applications. Parnitzki
proposed the digital control of heat pumps with a regulator
scheme based on regulation of a temperature difference in
the evaporator [2]. Vargas and Parise presented an effective

0196-8904/$ - see front matter  2007 Elsevier Ltd. All rights reserved.
doi:10.1016/j.enconman.2007.01.033
 Y. Zhao et al. / Energy Conversion and Management 48 (2007) 3146–3153 3147

Nomenclature

Ahf refrigerant side area of control volume (m2) r vapor latent heat (kJ/kg)
Ahw water side area of control volume (m2) t time (s)
B fuel consumption (kg/s) T1 inlet temperature of water cooling engine (C)
c clearance volume factor T2 outlet temperature of water cooling engine (C)
Cp specific heat of pipe wall at constant pressure T3 air temperature of condenser’s outlet (K)
(kJ/kg K) Te outdoor air temperature (K)
Cpa specific heat of air at constant volume (kJ/kg K) Tin temperature of refrigerant entering control vol-
Cpr specific heat of exhaust gas at constant volume ume (kg/s)
(kJ/kg K) T1 indoor air temperature (K)
Cw specific heat of water cooling engine (kJ/kg K) Tout temperature of refrigerant out of control volume
d pipe diameter (m) (kg/s)
Gw flux of water cooling engine (kg/s) Tpa air temperature of engine’s inlet (K)
Gw air consumption (kg/s) Tpr outlet temperature of exhaust gas (K)
hcp,out specific enthalpy in compressor outlet (kJ/kg) Tf average temperature of refrigerant (K)
hcp,in specific enthalpy in compressor inlet (kJ/kg) Tp average temperature of pipe wall (K)
hl liquid specific enthalpy of refrigerant in heat ex- Tw average temperature of water (K)
changer (kJ/kg) DT temperature difference (K)
hg gas specific enthalpy of refrigerant in heat ex- DTsh(s) evaporator outlet superheat (K)
changer (kJ/kg) DT 0sh ðsÞ receptive superheat (K)
K1, T1 characteristic factor Vcp compressor cylinder volume (m3)
K characteristic factor of expansion valve vcp,out specific volume in compressor outlet (m3/kg)
L length of control volume (m) x refrigerant quality
LHV low heat value of natural gas (kJ/N m3) apf coefficient of heat transfer between heat exchan-
mf,cp refrigerant mass flux (kg/s) ger and pipe wall (kJ/K m2)
min mass of refrigerant entering control volume apw coefficient of heat transfer between water and
(kg/s) pipe wall (kJ/K m2)
mout mass of refrigerant out of control volume (kg/s) x compressor speed (rps)
P pressure (Pa) k coefficient of discharge
Pc condenser pressure (Pa) kv volumetric factor
Pe evaporator pressure (Pa) kp pressure factor
DP difference between condenser pressure and evap- q refrigerant density (kg/m3)
orator pressure (Pa) qf density in expansion valve inlet (kg/m3)
DPs1 suction pressure loss (Pa) qg gas density of refrigerant in heat exchanger
Qb total heat from natural gas (kW) (kg/m3)
Qe effective shaft work (kW) ql liquid density of refrigerant in heat exchanger
Qr waste heat recovered from exhaust of gas engine (kg/m3)
(kW) c void factor
Qs heat loss (kW) c average void factor
Qw waste heat recovered from cooling water of gas
engine (kW)

control system in which a power law control action is intro-
duced to provide the necessary compressor speed variations
according to ambient conditions [4]. With the development
of artificial intelligence, there are also other new methods
introduced into the control schemes, such as the fuzzy set
theory, the function of the Smith predictor, the radial basis
function neural network and so on.
The fuzzy set theory is a theory about vagueness and
uncertainty and enables us to use non-precise, ill-defined
concepts and yet work with these in a mathematically strict
sense. When only imprecise or indefinite information about
the dynamic behavior of a process is available, fuzzy sets
can be used to build better models and controllers. Fuzzy
controllers have been implemented by many researchers
and good results were attained [5]. So, it is possible to com-
bine fuzzy set theory with the classical PID control
problems.
The function of the Smith predictor is to predict the pro-
cess variables well before it is possible to measure them.
When the appropriate measurement actually becomes
available, the synchronized error can be used to correct
the current model predictions [6].
Because the building load is continuously changing with
time due to changes in weather, equipment use and occupancy,
3148 Y. Zhao et al. / Energy Conversion and Management 48 (2007) 3146–3153

it is important to perform load prediction to reduce the

time delay of the indoor temperature. Here, the radial basis
function (RBF) neural network is introduced to predict the Expansion
Air flow Building
building load. The RBF is a two layer network consisting valve
of one Kohonen input layer and one output least mean Auxiliary
Surplus gas heater
squares layer. Detailed descriptions of the RBF network Condenser Evaporator
can be found in [7].
Each method has its unique merits and shortcomings Exhaust gas
when used individually, but if they are combined reason- Heat exchanger
ably, the shortcomings can be overcome and exact control
realized. So, in this paper, the authors put forward an intel-
Engine
ligent control scheme with the combination of the classical
PID algorithm and fuzzy control and Smith predictor as Compressor
the feedback part and the building load prediction using Cylinder
the radial basis function (RBF) neural network as the feed Heat
j kexchanger
forward part. A natural gas engine heat pump system
model is made to test the effect of the intelligent control
scheme, and the results are satisfactory. Refrigerant R134a Engine coolant

Air flow Surplus gas

2. System model
Water as secondary refrigerant

In recent years, there has been a great deal of results Fig. 1. Schematic diagram of the GEHP working in heating mode.
and investigations concerning models elaborated to simu-
late the behavior of heat pump systems. In this paper, a "  n1 #
simplified model of the GEHP system is developed to sim- n Pc n
W cp ¼ V cp xkv kp P e 1  ð3Þ
ulate the heating process. The model has been proved to 1n Pe
reproduce the actual behavior of the heat pump well and " 1 #
provides the foundation for analysis of the control scheme Pc n
kv ¼ 1  c 1 ð4Þ
[8]. Pe
The system model is composed of a natural gas engine DP s1
model, a compressor model, a condenser model, an expan- kp ¼ 1  ð5Þ
Pe
sion valve model, an evaporator model, a cylinder jacket
heat exchanger model, an exhaust gas heat exchanger
model and an auxiliary heater model. The cylinder jacket 2.2. Thermostatic expansion valve [12,13]
heat exchanger and the exhaust gas heat exchanger are to
recover waste heat from the cooling water and the exhaust The thermostatic expansion valve model is composed of
heat of the tail gas of the gas engine, respectively. The aux- the control unit and the flow unit. The two units are used to
iliary heater will be switched on when the temperature of adjust the flow velocity according to the superheat. Because
the supply water is lower than needed. Fig. 1 shows the of its small volume, the expansion valve is considered as
schematic diagram of the GEHP heating system. The flow adiabatic without any refrigerant mass variation in it.
routines of the different flow medium are denoted with dif- The enthalpy is assumed to be constant. So, in the flow
ferent line types. unit, the refrigerant flow is given by
pffiffiffiffiffiffiffiffiffiffiffi
mf ¼ K DP qf ð6Þ
2.1. Compressor [9–11]
while in the control unit, the relation between the receptive
No mass variation in the compressor is considered here, superheat and the evaporator outlet superheat can be given
so the mass flows at the inlet and outlet are the same, and a by
polytropic compression process is assumed. Then, the K1
refrigerant mass flux, mf,cp, can be calculated by the follow- DT 0sh ðsÞ ¼ ess DT sh ðsÞ ð7Þ
1 þ T 1s
ing equations:
V cp xk
mf;cp ¼ ð1Þ 2.3. Heat exchangers (plate type)
vcp;out
" 1 #
Pc n In this paper, a two zone model is utilized. The evapora-
k ¼ 0:98  0:085 1 ð2Þ tor is divided into two zones (evaporation and superheating
Pe
zones), and the condenser is divided into three zones
The power of the compressor is given by (superheating, condensation and subcooling zones). Each
 Y. Zhao et al. / Energy Conversion and Management 48 (2007) 3146–3153 3149

zone is considered as a control volume. In every control Similarly, the heat transfer coefficient in the superheated
volume, the equations of continuity, energy and momen- zone between the evaporator pipe wall and the refrigerant
tum are established. can be taken from the following correlation:
In the model, some assumptions are made: (1) the pres-
Nu ¼ 0:18Re0:18 Pr0:4 ð18Þ
sure drop along the pipes is not considered and the pressure
varies with time; (2) the heat loss is negligible; (3) the heat asup d
Nu ¼ ð19Þ
conduction through it is negligible. k
For every control volume, the following set of differen- while in the two phase zone, for the annular flow, the heat
tial equations can be written [9,14]: transfer coefficient is represented by [15]
k
• Mass conservation equation a00 ¼ 0:023 Re0:8 Pr0:4
l / ð20Þ
d l
d
f½ql ð1  cÞ þ qgcAhf Lg where / is a modification coefficient. The average heat
dt transfer coefficient between the water and the condenser
dL pipe wall can be derived from the following correlation
¼ min  mout þ ½ql ð1  cÞ þ qgcAhf ð8Þ
dt [17]:
• Energy conservation
Nu ¼ 0:023Re0:8 Pr0:4 ð21Þ
d dP
f½ql hl ð1  cÞ þ qg hgcAhf Lg  Ahf L while for the evaporator, it is given by [17]
dt dt
¼ apf AðT p  T f Þ þ min hin  mout hout Nu ¼ 0:023Re0:8 Pr0:3 ð22Þ
dL It is important to determine the thermodynamic and trans-
þ ½ql hl ð1  cÞ þ qg hgcAhf ð9Þ
dt port properties of refrigerant R134a. The P–R state equa-
• Pipe wall energy conservation tion is used here [18]:

dT p RT aðT Þ
Cp ¼ apw Ahw ðT w  T p Þ  apf Ahf ðT p  T f Þ ð10Þ p¼  ð23Þ
dt v  b vðv þ bÞ þ bðv  bÞ
• Water (secondary fluid) energy conservation
2.4. Natural gas fueled engine
dT w
Cw ¼ apw Ahw ðT w  T p Þ ð11Þ
dt Supposing that the natural gas engine is one-cylinder,
four-stroke and the speed can be adjusted between
The correlations utilized in this work to calculate the 1000 rpm and 3000 rpm, its related model can be found
convective heat transfer coefficients and void fraction are in Ref. [8]. The total fuel consumption of the engine can
listed as follows. The void factor is given by [10] be calculated by the following equation [8]:
1
c¼ 1 q ð12Þ B ¼ Qb =LHV ð24Þ
1 þ x  1 qgl
where the thermal value of the fuel per unit time can be cal-
So, the density in the two phase zone can be expressed as culated by the formulation in Ref. [8]:
q ¼ cqg þ ð1  cÞql ð13Þ
Qb ¼ 0:292 þ 0:011x þ 0:000479x2 þ 1:337143W
The heat transfer coefficient in the single phase zone (super-
heat or subcooling) between the condenser pipe wall and the  0:01139W 2  0:00075xW þ 0:000108xW 2
refrigerant can be taken from the following correlation [15]:  7:2  107 x2 W  5:3  107 x2 W 2 ð25Þ
0:72 0:3
Nu ¼ 0:18Re Pr ð14Þ
while in the two phase zone, it can be calculated by [16] 2.5. Heat exchanger for recovering the waste heat [19]
 0:8 !0:25
Rel 0:33 ql The model of heat exchangers for recovering the waste
Nu ¼ 0:0048 Pr ð15Þ
H qg heat can be described by the energy equilibrium of the nat-
where H is a dimensionless parameter for consideration of ural gas engine:
a liquid membrane and c 0 (J/kg) denotes the influence of li- Qb ¼ Qe þ Qw þ Qr þ Qs ð26Þ
quid membrane thickness and subcooling:
The heat recovered from the cooling water of the engine is
C p DT
H¼ ð16Þ Qw ¼ Gw C w ðT 2  T 1 Þ ð27Þ
c0
 
0 0:68C p DT and the exhaust gas heat is given by
c ¼c 1þ ð17Þ
r Qr ¼ ðB þ Ga ÞðC pr T pr  C pa T pa Þ ð28Þ
3150 Y. Zhao et al. / Energy Conversion and Management 48 (2007) 3146–3153
In the heating operation, the speed and load of the engine
changes with the heating load for the system, consequently,
the shaft work, the cooling water heat and the exhaust gas
heat changes, but for a given time interval, they can be con-
sidered as constant.
3. Solution method
The refrigerant in this system is HFC-134a, and the sim-
ulation is programmed by the SIMULINK software pack-
age of MATLAB 6.5 [20]. The system of differential and
algebraic equations provided by the mathematical model
is integrated numerically in time using a Runge–Kutta
fourth–fifth order algorithm with controlled step size [21].
Parts of the dynamic simulation results of the GEHP sys-
tem in heating mode are shown in Figs. 6–9.
4. Control simulation of system
The intelligent control simulation of the system utilizes
the prediction controller model and the combined control-
ler model.
The prediction controller model is developed with the
radial basis function (RBF) neural network to predict the
heating load of the building. The heating load of building
is a function of the climatic parameters, such as temperature,
solar radiation, humidity, etc. and the structure and location
of the building. The nonlinear relationships between differ-
ent parameters make it difficult to model the building load.
The RBF has many strengths, such as its strong ability for
nonlinear relationships, no need of physical models and
self-learning. It is made up of three layers, as shown in
Fig. 2. For a specified building, its load is independent of
its structure and location, so the current building load model
has not taken them into consideration. The load prediction
model must be trained before its use. The training data comes
from Ref. [22]. After training with 198 sample data, the RBF
is successful in predicting the building load. In the test of the
RBF prediction model, the prediction accuracy is within
±9%, as shown in Fig. 3. During the GEHP operation, the
RBF prediction model forecasts the building load for the
next moment. A time lag exists between the load variation
Time
Outdoor temperature
Indoor temperature
………
………
Solar radiation
Humidity
Building load at
time (t-1)
Fig. 2. The RBF prediction model.
32
31
30
Q(kW)
29
28
27
Sample
Prediction
26
8 9 10 11 12 13 14 15 16 17 18 19
time(h)
Fig. 3. Comparison between RBF building load prediction and sample.
and the return water variation. The prediction controller will
work timely to make up the hysteretic effect of the tempera-
ture of the return water. It makes the controller and the
GEHP system react in advance to the variation of the build-
ing load. It kills the influence of disturbances and improves
the dynamic characteristics of the system.
The fuzzy controller has strong robustness, but because of
its responding to the output error and the change-in-error
and its multi-level relay property, the fuzzy controller has
bad steady state accuracy and great control error. For the
GEHP system, it is important to control the steady state
error of the outlet water temperature. So, the fuzzy controller
should be improved so that it can improve its steady state
accuracy. The PID control can increase the steady state accu-
racy and reduce the overshoot of the system, but its response
speed is slower. The combination of the fuzzy control with
the PID control can realize good steady operation, but
because of the time delay of the GEHP system, especially
when the dynamic delay is very big, great overshoot, bad sta-
bility and even oscillation will occur in the control process.
Therefore, the Smith predictor compensation is added to
the combination of the fuzzy control and the PID control
to form the combination controller. It can decrease the hys-
teretic influence and increase the stability of the system.
Building load at
time (t)
 Y. Zhao et al. / Energy Conversion and Management 48 (2007) 3146–3153 3151

Indoor
temperature
ke e E Fuzzy contr -
+ Fuzzy Fuzzy U
Non-fuzzy u
A/D process D olling rule process ko
d decision
d/dt kd
-
Gas engine heat pump Speed adjuster D/A
of gas engine

Fig. 4. Diagram of fuzzy control principle.

Fig. 4 depicts the diagram of the fuzzy control principle. The control action of the intelligent controller is summa-
Its input and output variables are listed as follows: rized below:

Input variables: deviation between the temperature of the
supply water and the desired setting value – e (1.0 to
1.0 C), deviation variance rate – e (0.01 to 0.01 C/s);
Output variable: fuel consumption of the gas engine – B
(1.0–2.5 N m3/h).
• Real time tracking of the influence of weather changes
on the building load through the load prediction.
• Based on the feed forward prediction of load, accurate
control of the system by the feedback controller is
accomplished.

The decision making rules for the fuzzy control are sta-
ted as follows:
• If e is bigger and e is increasing, B should be greatly
increased.
• If e is smaller and e is decreasing, B should be slightly
reduced.
• If e goes to zero and e does not vary, B should be kept
invariable.
So, the two parts of the intelligent controller can be
illustrated as follows: The feed forward part predicts the
load of the building through the radial basis function
(RBF) neural network (prediction controller). The feed-
back part is the combination control of fuzzy control with
Smith control and PID control (combined controller).
Once the GEHP is on, the compressor will run with
accelerating speed. The combination controller acts
according to the deviation between the setting value and
the actual value of supply water temperature, while the
RBF predicts the building load for the next moment and
reflect in real time the change to the prediction controller
at the same time. Then, a control action will be done. If
the temperature deviation lies between 0.02 and
0.02 C, the fuzzy controller will be cut off and the PID
controller will act. The smooth transition between the
two controllers avoids oscillation. On the contrary, if the
deviation lies beyond the range of 0.02 to 0.02 C, adjust-
ment will be made according to the fuzzy rules. The above
process will continue until the system reaches steady state
operation. The diagram of the intelligent control principle
of the GEHP system is shown in Fig. 5.

Meteorological Meteorological
Other parameters variation
parameters

Load prediction Building

Temperature of returned water

Initialized temperature +
GEHP unit Temperature of
+ Combined +
controller supply water

Intelligent controller

Fig. 5. Diagram of intelligent control principle.

3152 Y. Zhao et al. / Energy Conversion and Management 48 (2007) 3146–3153

5. Results and discussion 0.4

To test the effects of the intelligent control scheme, two

0.35
cases are studied: (1) 5000 s of operation with constant out-

B(Nm 3 /h)
door air temperature and (2) 8000 s of operation with
abrupt change of outdoor temperature. Figs. 6 and 7 refer 0.3
to case (1) and Figs. 8 and 9 refer to case (2). In both cases,
the desired setting temperatures are 21 C, and the original
outdoor and indoor air temperature are both supposed to 0.25

be 7 C.
Figs. 6 and 7 show the dynamic simulation results of the 0.2
compressor speed and indoor temperature with constant 0 2000 4000 6000 8000

outdoor temperature of 7 C. It is found that the compres- t(s)

sor speed decreases quickly to a minor value after running Fig. 8. Dynamic variation of fuel consumption under falling outdoor
for 800 s, and it takes 900 s for the indoor temperature to temperature conditions.
reach the setting value for the first time. At around
1000 s, the compressor speed rises slightly and then
22
achieves steady state operation. The highest temperature
of the controlled room is 0.2 C higher than the desired set- 20
ting value. The overshoot is 1.5%, and the steady state 18
error approximates zero, which shows that the dynamic
16
and steady state characteristics of the scheme are
satisfactory. T(˚C) 14

Figs. 8 and 9 show the dynamic simulation results of fuel 12

consumption and indoor temperature with an abrupt 10

55 6
0 2000 4000 6000 8000
t(s)
50 Fig. 9. Dynamic variation of the controlled room temperature under
falling outdoor temperature conditions.
n(r/s)

45
change of outdoor temperature. The initial operation is
the same as in case (1), but at 4000 s, the outdoor air tem-
40
perature falls by 5 C. It can be seen from these figures that
when the outdoor temperature changes, the indoor temper-
35
ature will fluctuate and then get to its steady value quickly,
0 1000 2000 3000 4000 5000 but vibration does not appear. Although the steady state
t(s) error increases at the same time, it is still acceptable. It also
Fig. 6. Dynamic variation of compressor speed. shows that when the difference between the indoor and out-
door temperature increases, the fuel consumption of the
gas engine will go up fast and then tend to a constant value
22 in a short time. Therefore, the control scheme has good
20 adaptability for disturbances caused by shifts of outdoor
temperature.
18

16 6. Conclusions
T(˚C)

14

12
(1) A simplified model of the GEHP system has been
constructed to simulate the heating process. It has
10
been proved to reproduce the actual behavior of the
8 heat pump well, and it provides the foundation for
6 the analysis of the control scheme. It is effective in
0 1000 2000 3000 4000 5000
analyzing the effects of the control system and the
t(s)
dynamic variation of performances in the operation
Fig. 7. Dynamic variation of the controlled room’s temperature. process.
 Y. Zhao et al. / Energy Conversion and Management 48 (2007) 3146–3153
(2) An intelligent controller is developed in this paper. It
is composed of a prediction controller and a combi-
nation controller. The prediction controller based
on the RBF neural network can be used for predict-
ing the building load at the next moment. The com-
bined controller consists of a PID controller, a
fuzzy controller and a Smith controller. The simula-
tion results show that its dynamic and steady charac-
teristics are satisfactory. The intelligent controller can
eliminate the disadvantages of long time delay, large
inertia and nonlinearity of the heating system and
achieve good steady state accuracy and dynamic
characteristics.
(3) It is feasible to use the intelligent controller in the
heating system to realize energy saving and comfort.
Acknowledgement
This project was supported by NSFC, the National Edu-
cation Department for Doctor Center Foundation, the
Tianjin Science and Technology Development Project
and National 863 Program.
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