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If they did, do these other documents override the previous if the previous was not revoked?
It depends on the wording. You can draft a POA that will "revoke all prior POAs" or you can do a POA that doesn't mention the prior ones and thus both people would have a POA that could be used.
when and how to report the abuse without causing more trouble for him at home
I'm not sure what you mean by this, but if you call Adult Protective Services they are going to start an investigation immediately. At some point you may be asked under oath when you suspected abuse and if there is an extended period of time between when you suspected it and when you reported it then you won't be considered as a guardian if that becomes an issue and there could be other problems as well.
Can any of us (me or my siblings) go pick him up and fly him home with us?
This is a difficult question. The law doesn't really have anything to say on this matter one way or another. Your father can certainly make the decision to come with you so long as there isn't a court order stating he is "incompetent" or "incapacitated", which usually only happens when someone has sought a guardianship and you should have been served with papers if that happened. However, if he signed a POA to her, revoking the prior POA then she can forbid it based on that POA and the police won't do anything (usually) except tell you that you need to talk to a lawyer.
What you and your siblings may want to discuss is contacting a local lawyer and talking to them about the possibility of one of you filing for guardianship. It is a reasonably complicated matter in Texas but this exact set of facts happens waaaaay more often then you would think.