Heat exchangers play a crucial role in thermal management and in enhancing heat transfer efficiency within hydraulic systems. This study emphasizes the importance of precise design and computational analysis for optimizing exchanger performance and effectively controlling temperature. Computational Fluid Dynamics (CFD) simulations were employed to predict the internal and external flow behaviour and to analyse temperature distribution within the heat exchanger. Key parameters, including flow velocity, pressure, temperature, and heat distribution in both the tubes and the shell, were thoroughly examined to provide a comprehensive understanding of flow characteristics, turbulent structures, and thermal behavior. The primary objective of this research was to optimize a thin-walled helical tube heat exchanger to maximize heat transfer efficiency. Wilson design methods were applied to determine optimal parameters such as tube spacing, diameter, and flow rate. The helical configuration enhances turbulence, increases the fluid contact area with the walls, and improves heat transfer. This compact design reduces the exchanger length to 4.2 meters while maintaining equivalent thermal capacity. Simulation results indicate that turbulent flow increases fluid mixing and enhances heat exchange between hot and cold fluids. Optimization of the thermal boundary layers significantly improves heat transfer performance, achieving a thermal efficiency of 76% and a 71% enhancement in the Nusselt number compared to similar studies.