Heat exchangers are critical components in power plants, refrigeration systems, chemical processing, and thermal management applications. Improving heat transfer efficiency while minimizing pressure drop remains a major challenge in mechanical engineering. This research investigates the effect of twisted tape inserts on heat transfer enhancement in a shell and tube heat exchanger through experimental and theoretical analysis. Experiments were conducted under varying flow rates and inlet temperatures to evaluate heat transfer coefficients, Nusselt number, and friction factors. The results demonstrate a significant improvement in heat transfer performance with twisted tape inserts compared to a plain tube configuration. The experimental findings show good agreement with theoretical correlations. The study concludes that twisted tape inserts offer an effective and economical method for improving thermal performance in heat exchangers.