Hi,
The debug information you posted previously doesn't correspond to the order on your screenshot.
On your order, the total weight is 23lb and the total volume is 4312 in^3, but in the debug you posted before the weight is only 12lb and the volume is 12*22*7=1848in^3.
This probably explains the different result between the shipping cost provided by the carrier in the debug and the shipping cost in the order since the package is twice as heavy and more than twice as voluminous.
So I think the problem is not with the settings of the shipping method, but with the way you're doing your shipping cost tests.
Maybe, for example, you have two products with the same name, but not the same weight / dimensions, and that's where the difference comes from ?
Note that the shipping costs is only requested to the carrier on the checkout for carts. At that point, the order number the future order will have is not yet known. So it's normal you can't find the order number in the debug information.