How about crunching that down to a small runable sample that demonstrates the problem you are having?

BTW, there seem to be a huge number of global variables there. Probably nothing to do with your problem, but good programming style avoids them like the plague. Looks like a bundle of variables are used as though they are locals but are not declared locally with my. Life time control tends to clean up a large range of subtle bugs.

Oh, and if you are not using strictures (use strict; use warnings;) you really ought!