Seems to me aioEnable somehow triggers this.
It maintains buffers of size FD_SETSIZE (1024 on Linux)*, so an fd
parameter** >= that, could probably trigger such an error.
Maybe you could put a halt in whichever method in OSSubprocess/OSProcess
calls the primitive triggered when condition occurs, to see if that is the
cause? 
If so, identifying *why* you end up with fd's that high (which, afaik, isn't
normal), will probably lead to a workaround/solution...

Cheers,
Henry

*
https://github.com/pharo-project/pharo-vm/blob/e0ce2d9d78c3c7b37bbc12cd8730c6a15f1f057c/opensmalltalk-vm/platforms/unix/vm/aio.c
**
https://github.com/pharo-project/pharo-vm/blob/c50dec02d2875de56c84d11889c78484e2d5cda8/mc/VMConstruction-Plugins-AioPlugin.package/UnixAioPlugin.class/instance/primitiveAioEnable.st



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