This is mostly DB related stuff. Make sure both prod and nonprod remedy servers are on same version/patch level.
1. Backup DB from Prod Remedy Server.
2. Stop Dev Remedy server
3. Restore Prod DB backup on Dev DB. (In case of SQL Server DB, You need to take care of DB owner ARAdmin.Sometimes It creates two instances of ARAdmin user after restore).
4. Start Dev Remedy AR Server.
Once server is up, You need to update remedy server references in multiple forms.
You can use this utility as well to update server references:
BMC supplied link for removal of Server References. Very recently did the same and used below link for update of Server references.
Some similar link.