Davefitz,
We had two flow elements crack and leak a few years ago. We made temporary weld repairs then replaced them with an all P91 design. Besides, the 625 filler will embrittle at PWHT temps according to EPRI. Good luck.
I suggest you try the Modified Currans etch. The recipe that we use is 10g FeCl, 30ml HCl, 150ml H20. Practice in the lab to establish the reaction time before you take it to the field. We like this etchant because it gets away from the picric although I think Vilella's is still the best...