Hi Tony,
Sorry, I don't know the code used for the export to Excel. If the Save As works for you consistently can you re-write your code to call to that command instead of copy/paste?
I'm not sure why you are experiencing intermittent hiccups on the copy/paste. There are several "don'ts" in Project - one is blank rows - my concern is especially if you are developing the code for other users, it is tough to control what they may have done in the Project file.
The export to Excel just drops the data and may be more predictable.
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