Datafiles Mismatch in production & disaster recovery server

Datafiles Mismatch in production & disaster recovery server though everything in sync
We performed all the necessary prerequisites & processes related to DRS switchover successfully also our DRS server is constantly updated through logs application in mount state whan we opened DRS database in mount state it opened successfully however when we issued command
Recover database
It dumped with foll errors:
ora-01122 database file 162 failed verification check
ora-01110 data file 162 </oracle/R3P/sapdata7/r3p*****.data>
ora-01251 unknown file header version read for file 162
as I do not remember the exact name now
However upon comparing the same file at production(which was now in shutdown state) the file sizes were mismatching so we went ahead to copy the datafile from production to DRS in database shutdown state at DRS through RCP utitlity of AIX 5.3 since our Operating system is AIX 5.3
Though this remote copy was success
we again started database in mount state & issued command
Recover database
But still it dump the same error but now for another datafile in DRS
I mean I would appreciate if somebody could point out that despite our DRS was constantly being updated through our Production in terms of continuous log application before this activity logs were sync in both the systems also origlos,mirrorlogs & controlfiles were pulled from production system as it is infact the whole structure was as replica of production system , then why did datafile sizes mismatch??
Details
SAP version :- 4.7
WAS :- 620
Database :- Oracle 9.2
Operating system :- AIX 5.3

I am in a process of DR Planning.
My present setup :
O/S : HP-UX 11.31
SAP ECC 6
Oracle 10g Database.
I know about dataguard and i have implemnted same on our other application but not for SAP.
I have ame doubts and I request you to please guide me for the same.
1. SAP License key -- it required hardware key. So will i have to generate license key another hardware key i.e. for machine where standby database.
2. Database on standby site will be in manage recovery mode. Will I have to make any changes or any other file realted to SAP on standby host ? (some i know such as I upgrade SAP kernal, same i have to upgrade at standby host)
Will you give me some link related to document for DR

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