now some days later opening the file on another machine the ports are all mis-sized again, this time usually too long and overlapping the net label
i remembered this was maybe "Orcad Ports" it was checked on this machine i unchecked it, no change
Just so that it is 100% clear, when "Orcad Ports" is checked, ports are changed to the fixed size supported by OrCAD. No memory is kept of the original settings. The option is used to allow export to OrCAD, so, for a file to be consistent back and forth, the port size settings must match the OrCAD requirements.
So when you uncheck it, nothing happens. Except that if you resize the ports this time, they will stay resized unless you open up the file in Protel with Orcad Ports checked again. Which is what you did.
If you have any control over it, I'd suggest using OrCAD ports if it is not uncommon to need to interchange files with OrCAD. Otherwise the option should stay unchecked and you can take advantage of the more flexible Protel ports.
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