Shortened to 54 holes by the weather, 31 year-old Fernandez-Castano had sank a 9 ft birdie on the 18th, ending on 14 under alongside Juvic Pagunsan of the Philippines.
The Spaniard could have tied things up sooner but suffered three bogeys on the back nine and hit his final tee shot into the water. A superb escape and 20 ft putt saw him finish with a final round 72 and the play-off.
With a final round of 67 Pagunsan steadily climbed the leaderboard, taking advantage of Fernandez-Castano bout of poor putting to claw back the Spaniard's three shot advantage from the start of the day.
Pagunsan had a golden opportunity to take the title on the first extra hole but the 5 ft putt was pushed wide and the pair returned to the tee.
Once more the Filipino set up a birdie opportunity but when he missed form 10 ft, Fernandez Castano putted form a foot closer to claim the title and his fifth European Tour win since 2008.
He said:
"This is probably the most nervous I've ever been on a golf course. [Sunday] was the type of pressure I have never felt before. I've never been in the lead with a four shot margin going into the last nine holes. I hope I've learned from that."
The Spaniard had missed six months of the season with a back injury and had not won on the tour since taking the British Masters title in 2008.
England's James Morrison, placed three shots of the lead after the second round, failed to close the gap after bogeys on the 11th and 18th.
Countrymen Justin Rose was tied for ninth on 10 under after shooting a final round 69, while Graeme McDowell ended with a superb 66 to end on 8 under.





