All I can think of is that this may be related to one instance of Sigil writing to the Settings and somehow locking it which prevents others from reading it successfully. Mixing versions of Sigil may also be an issue if new settings have been included and old settings removed.
We have had a number of changes to the settings in recent releases.
I can not recreate this on a Mac at all, but there are never multiple instances of Sigil running on a Mac, there are just multiple main windows all from the same main process all sharing the same settings file so the problem case simply can not trigger in this type of environment.
KevinH
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