Noel,
I am not at the DAW for the next six hours but I will address your suggested tests before the night is out.
The project only opened twice today when I got the noise with no crash. After that I was unable to open project without excluding all UAD plugs (1176 newer version, LA-2A, Helios maybe one more). And then, I could not reproduce the noise.
Specs:
SONAR X64, WIN 7 64bit, UAD Ver 5 or 6 (I cannot recall which) on two UAD Quad cards.