Bearing apparatus including a bearing assembly having a continuous bearing element and a tilting pad bearing assembly

A bearing apparatus, comprising

• a first bearing assembly including:
• a first support ring;
• and
• a plurality of tilting pads each of which includes a superhard bearing element having a polycrystalline diamond bearing surface, each of the plurality of tilting pads tilted and/or tiltably secured relative to the first support ring;
• and
• a second bearing assembly including:
• a continuous superhard bearing element including a continuous superhard bearing surface that includes a non-polycrystalline diamond material including reaction-bonded silicon nitride or reaction-bonded silicon carbide, the continuous superhard bearing surface generally faces the superhard bearing element of each of the plurality of tilting pads, the continuous superhard bearing element having a maximum lateral width greater than about 2 inches.

A method of operating a bearing apparatus, the method comprising:

• rotating a rotor relative to a stator;
• wherein at least one of the stator or the rotor includes:
• a first support ring;
• and
• a plurality of tilting pads each of which includes a superhard bearing element having a superhard bearing surface, each of the plurality of tilting pads tilted and/or tiltably secured relative to the first support ring;
• wherein the other of the stator or the rotor includes:
• a continuous superhard bearing element including a continuous superhard bearing surface that generally faces the superhard bearing element of each of the plurality of tilting pads, the continuous superhard bearing element having a maximum lateral width greater than about 2 inches, the continuous superhard bearing surface including reaction-bonded silicon nitride or reaction-bonded silicon carbide.

A method for manufacturing a bearing assembly, the method comprising:

• providing a continuous superhard bearing element that includes a continuous superhard bearing surface including reaction-bonded silicon nitride or reaction-bonded silicon carbide;
• forming a hole generally in a center of the continuous superhard bearing element;
• providing a support ring including a recess configured to receive the continuous superhard bearing element;
• attaching the continuous superhard bearing element to the support ring such that the continuous superhard bearing element is secured in the recess of the support ring;
• and
• smoothing the continuous superhard bearing surface of the continuous superhard bearing element to exhibit a surface finish of less than 20 microinches.