Sorry to hear about the problems you're having. For number 2, if you would like us to troubleshoot this problem of TIN files becoming invalid, please post your data and workflow to reproduce. For number 3, there should be no problem updating surfaces on ProjectWise. If you would like us to troubleshoot, provide data and a workflow. For number 4, take a look at this article and see if it helps any: communities.bentley.com/.../components-do-not-display-when-running-draw-cross-sections-from-surface-command.aspx
Have you had a chance to try the new OpenRoads Corridor Modeling tools yet? The differences between InRoads and GEOPAK go away for the design tools in the SS3 releases. We've been working with several DOTs to get them up and running in SS3.