I missed a bit
"Also we took another copy of the same images earlier but that time it took 3 tapes and the 3 of them were never used(scratch tapes). How would I technically justify this?"
Kinda following on from my previous comment, talk to the tape drive vendor, as per my explanation, absolutly nothing we can do to control this in NBU.
Yes, buffer size can make a massive difference in performance - it can be the differene between the drive runnining at of near it's maximm speed, to so slow, it's quicker to write the data out by hand ...
Drives running slow have to stop-start, as they run out of data to write andhave to wait, this can absolutly wreak them - LTO are not designed for this, they need to 'stream' - so buffer size has more than just an impact on performance.
"bpimport status = media read error"
Impossible to say - NBU does not read or write to tapes itself, that is all done by the operating system, we just send the data and say please get this on a tape using buffer size X. The majority or read /write errors are outside of NBU (despite popular opinion) - but we are ususally looking at worn out drives/ faults / firmware issues etc ...
Tape in theory is massivly reliable, more so than disk, but only it treated correctly - kept in the correct environmental conditions, made sure data always streams to it, not handled incorrectly (dropped, knocked about when being moved) ... but even so, it will wear out eventually, depending on it's age. That said, it's harder to write to a tape then read it ('signal' strength needs to be higher to write), so I'd expect, for a worn out tap, the writes to start to fail before the reads.
Could be worth trying the tape in another drive, sometimes drives have an issue only with certain tapes (usually when thing are older and getting worn).