My take on "blowouts" is impatient or panicked users. They either ctl-alt-del before a process is completed or do something like hitting the power cord or power switch during a process that is doing read/write. Or, my personal favorite, killing the job during a purge they accidentally started. If a report is being generated when they abort the program abnormally, it will sometimes hang print jobs subsequent users try to generate. Initializing reptpass usually fixes this problem. Since it is a temporary file & cobol based, I doubt if your oe header problem could be related. The reptpass file is used by all apps & is updated everytime a print job is processed. I imagine the printing pick tickets & pack slips update reptpass, but probably not select for billing, which produces no report but changes order status. Only on demand billing reports should update reptpass.
You might consider if you have a page locking issue with the access upload on your btr file. Though, why it would delete records rather than warn is mysterious. Creating orders externally is a pretty complex process, so there could be lots of possibilities. Good luck.