I seem to have sorted the problem I was having. I have renewed my dark frame library and prepared masters in Pixinsight using the Image Integration tool. Same for master bias. Loaded my lights, darks master, bias master, flats and flat darks to BPP and all worked fine. I had found a problem with the fits header in my dark library; I made the library a year ago with Nebulosity v2, the headers are different to the images I am now taking in Neb v3, so that seems to be where part of the problem was. I also experienced a problem with the bias frames I recorded a few days ago; they were 2 rows and 2 columns short of the dimensions of my other frames; I reran them today and they were the correct dimension - haven't a clue why this occurred - same camera, same laptop, same software.
Fingers crossed, problem solved.
Regards
Gordon