Secondary flows in Francis turbines are induced by the presence of a gap between guide vanes and top–bottom covers and rotating–stationary geometries. The secondary flow developed in the clearance gap of guide vanes induces a leakage vortex that travels toward the turbine downstream, affecting the runner. Likewise, secondary flows from the gap between rotor–stator components enter the upper and lower labyrinth regions. When Francis turbines are operated with sediment-laden water, sediment-containing flows affect these gaps, increasing the size of the gap and increasing the leakage flow. This work examines the secondary flows developing at these locations in a Francis turbine and the consequent sediment erosion effects. A reference Francis turbine at Bhilangana III Hydropower Plant (HPP), India, with a specific speed (Ns = 85.4) severely affected by a sediment erosion problem, was selected for this study. All the components of the turbine were modeled, and a reference numerical model was developed. This numerical model was validated with numerical uncertainty measurement and experimental results. Different locations in the turbine with complex secondary flows and the consequent sediment erosion effects were examined separately. The erosion effects at the guide vanes were due to the development of leakage flow inside the guide vane clearance gaps. At the runner inlet, erosion was mainly due to a leakage vortex from the clearance gap and leakage flow from rotor–stator gaps. Toward the upper and bottom labyrinth regions, erosion was mainly due to the formation of secondary vortical rolls. The simultaneous effects of secondary flows and sediment erosion at all these locations were found to affect the overall performance of the turbine.

In traditional short-term hydropower scheduling problems, which usually determine the optimal power generation schedules within one week, the off-design zone of a hydraulic turbine is modeled as a forbidden zone due to the significantly increased risk of turbine damage when operating within this zone. However, it is still plausible to occasionally operate within this zone for short durations under real-world circumstances. With the integration of Variable Renewable Energy (VRE) into the power system, hydropower, as a dispatchable energy resource, operates complementarily with VRE to smooth overall power generation and enhance system performance. The rapid and frequent adjustments in output power make it inevitable for the hydraulic turbine to operate in the off-design zone. This paper introduces the operating zones associated with various production costs derived from fatigue analysis of the hydraulic turbine and calculated based on the turbine replacement cost. These costs are incorporated into a short-term hybrid scheduling tool based on Mixed Integer Linear Programming (MILP). Including production costs in the optimization problem shifts the turbine’s working point from a high-cost zone to a low-cost zone. The resulting production schedule for a Hydro-Solar hybrid power system considers not only short-term economic factors such as day-ahead market prices and water value but also lifetime hydraulic turbine cost, leading to a more comprehensive calculation of the production plan. This research provides valuable insights into the sustainable operation of hydropower plants, balancing short-term profits with lifetime hydraulic turbine costs.