A similar thing happend to me once. I never had any CTD's when loading or reloading a saved career until this one time where I had done an overwrite to a save.
In patrol I save after every ship I sink - bw1, bw2, bw3 and so on. Once I saved over a previous save, let's say bw3, and it accepted the overwrite fine.
The next day I tried to load that save and it started to load and then CTD. Tried several times. Then I loaded the save just behind it - bw2 - and it launched fine and it was just minor set back.
I don't think this has anything to do with your setup or mods. Did you do an overwrite to a previous save?
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