This paper presents an analytical method, application of expansion, mechanical design, and integrated expansion design of subsea insulated pipe-in-pipe (PIP) systems. PIP system consists of a flowline and a casing pipe for the transport of high temperature and high pressure product from the subsea wells. To prevent heat lass from the fiowline, insulation material is applied between the pipes. The fiawline pipe and the casing pipe have mechanical connections through steel ring plate (water stops) and bulkheads. Pipeline expansion is defined by temperature, internal pressure, soil resistance, and interaction force between the flowline and the casing pipe. The results of the expansion analysis, the mechanical design of connection system of the two pipes and tie-in spool design are integrated for the whole PIP system.