Oracle Database Discussions

Gurus -

I need your help....I'm creating a development database for user testing. I put PROD in hotbackup mode, copy the db and arch files to development server. After creating the controlfile for the dev database attempt to recover database until cancel using backup controlfile and get the error message ora-19909. I did an alter database backup controfile to trace. used the generated controlfile from the trace file attempted to do the recover database until cancel using backup controlfile and got the same message (ora-19909).

Only thing that change since the last refresh was an additional of a datafile in PROD. We have used this same method for 2 years with out error, what could be wrong and how to resolve this??