Packing Geometry and Polymer Material Effects on Sealing of a PN650 Hydrogen Service Needle Valve: Vacuum/Helium Leak Screening and 650 Bar Hydrogen Cycling

External leakage from valve stem packings is a critical safety and reliability issue in high-pressure hydrogen systems. This work aims to quantify how packing geometry and polymer selection influence stem sealing in a PN650 needle valve (316L body and stem). Two geometries were compared: a conical V-ring (chevron style) stack and a flat three-disc stack. Two polymer material sets were assessed: Vespel® polyimide (SP-1/SP-21) and a glass-filled PTFE sealing element combined with a virgin PEEK back-up ring. Four assemblies (one per geometry/material combination) were first screened by hydrostatic pressure hold testing up to 1500 bar and by helium mass spectrometer leak measurements under vacuum. All assemblies sustained the hydrostatic overpressure hold with negligible decay. Vacuum helium screening produced leak rates between 3.7 × 10−10 and 9.5 × 10−10 mbar·l·s−1, with the conical V-ring geometry consistently outperforming the disc stack. A more demanding helium test at 700 bar with external vacuum yielded leak rates of 3.6–3.7 × 10−8 mbar·l·s−1, for conical assemblies. Based on the screening results and practical industrial considerations, the PTFE/PEEK conical configuration was selected for endurance testing and completed 2500 open/close cycles in 650 bar hydrogen without gland readjustment. Post-cycling checks confirmed continued tightness, including a qualitative helium pressure hold result near 700 bar and 0 bubbles in 10 min in the seat tightness test. Microscopy/EDX revealed limited wear with minor metallic transfer. The proposed multi-stage workflow provides a pragmatic route for the early qualification of stem packings for high-pressure hydrogen valves.