I actually don't quite know what is going on here.
But I do know that my listening observation of level is correct. Note this key thing on the graph:
Once I calibrated the headphone, I measured the output of the headphone amp and that is what I am reporting above: 0.27 volts. This is a quarter of the output of my Samsung S8+ phone output! My standard for sufficient volume for a 300 ohm headphone is 2 volts, not 0.27 volts.
I am using Topping A90 to drive headphones. For HD800S it was in low gain and volume control set to about 12 o'clock to get the above 94 dB. So that should also tell you that the playback level was not loud.
The drive unit I am using for the mic preamps has an amplifier as well. The default is supposed to be unity gain but maybe it isn't. I have to open it to find the setting.
For now, let me assure everyone that 94 dB as tested was not loud at all. Not only did I think music was too soft, I could listen to the full sweep with almost no discomfort. With speakers and at much longer distance, I have to wear hearing protection.
My main purpose for calibration was to get the two channels the same. It was a pain to do with the GRAS fixture as you have to remove the pinna and deal with very delicate wires inside. And the software in AP for calibration is made poorly making the process more aggravating than it should be.
So more work to do to refine the measurements but the results are not impacted.