Ok, probably I can answer my own question now.

The reason why the custom action cannot be fired is due to the wixlib being 
used to author our x86 components and the wixlib is referenced, together with 
other x64 ones, to build final x64 MSI. The customactionref was added into the 
wixlib part but seems this extra hierarchy prevented it from being fired during 
patch install. It is strange though, no problem to fire it if the upgrade MSI 
is installed. Neither the ORCA can tell any difference when customactionref is 
inside wixlib part vs outside - probably never meant to be for those 
pre-compilation info.

From: Hao Liu [mailto:hao....@cactuscommerce.com]
Sent: Thursday, August 30, 2012 2:23 PM
To: Windows Installer XML toolset developer mailing list
Subject: Re: [WiX-devs] cannot launch custom action during patch install

Btw, forgot to mention, I checked the patch install log, there is no any 
indication on the new custom action is called or not. Searching new custom 
action name in the log returned no hits.

From: Hao Liu 
[mailto:hao....@cactuscommerce.com]<mailto:[mailto:hao....@cactuscommerce.com]>
Sent: Thursday, August 30, 2012 1:50 PM
To: wix-devs@lists.sourceforge.net<mailto:wix-devs@lists.sourceforge.net>
Subject: [WiX-devs] cannot launch custom action during patch install

Hello Wix Devs,

I have a question for the problem I am currently working on with launching a 
new custom action during a patch install:

Basically I need to launch an EXE file while is installed by the original MSI 
during the patch/MSP install. The original MSI does not include this custom 
action so I authored it in the upgrade MSI (add the customaction definition as 
well as the installexecutesequence). Also in order to have it included in the 
patch, I add the customeactionref to this new added custom action into the 
patchfamily. The customaction definition and installexecutesequence are defined 
inside the same fragment so both get picked up by the MSP.

Now, I can see both customaction definition and installexecutesequence are 
shown up with the patch (using ORCA to load original MSI then view patch MSP). 
Everything looks correct except when patch is installed, the EXE is not 
launched. I have played with the condition for installexecutesequence even 
tried remove any condition - meaning should launch it unconditionally. Still no 
luck.

When I tried installing the upgrade MSI, the EXE is launched as expected. So 
just cannot have it work with patch install.

Any suggestions?

Thanks

Hao

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