Flames overshooting the radiants is often excessive flue pull, check if restrictor in plce (for 9x9). However that does not tie in with failed spillage test, did you leave fire runnig for the max 15 minutes?
Overgassing could result in spillage and overshooting of flames.
IMO a new ods is a wate of money - you sopuld have sorted other problems first (assuming fire not cutting out). Having to change ODS on a service for "free" warranty is scandalous - they rarely fail. I beleive they make the stipulation so that few extended warranties are actually valid for long. Evan Faecal Point have droped the requirement