Yep, they will never agree unless everything is done in local currency. What about using the multi-currency option in Project Server and then convert manually to USD? You understand that multi-currency will never match exactly so someone has to be off. You can enter costs in Project Server at the currency of choice, but then will need to use the same reporting the other way around to convert the cost to USD. Unfortunately Project Server only allows for entry in a local currency but does not have the capability to provide the conversion out of the box. Sorry, no perfect answer…just some thoughts.