Good news is that I've seen this before (a few times over the last several years), though not with expense reports, but with journal entries. Bad news is that every time I bring this to support's attention we're completely unable to replicate it and/or find a way to permanently fix it. So every time it's just been either I kill the workflow and re-initiate it (and have the approvers approve again) or create a temporary transition to manually push the transaction to the state I want.