Is test environment *same* as production server environment? (ie, production Linux, test is linux). Others might disagree, but think there is enough of a difference to make a difference.
When you did the search and replace did you literally search 'moodle' and replace with 'moodletest'? The reason for search and replace is to correct the URL's that Moodle constructs and uses in the DB so the search should have been for: http://productionsite/moodle/ replace with http://testsite/moodletest/ - using the full url's and trailing slash.
Could be that you've in-advertently replaced some other 'moodle' item related to file system that's causing the issue.
That's my best guess ... 'spirit of sharing', Ken