A methodology is presented for global sensitivity analysis of consequence models used in process safety applications. It involves running a consequence model around a hundred times and using the results to construct a statistical emulator, which is essentially a sophisticated curve fit to the data. The emulator is then used to undertake the sensitivity analysis and identify which input parameters (e.g. operating temperature and pressure, wind speed) have a significant effect on the chosen output (e.g. vapour cloud size). Performing the sensitivity analysis using the emulator rather than the consequence model itself leads to significant savings in computing time. To demonstrate the methodology, a global sensitivity analysis is performed on the Phast consequence model for discharge and dispersion. The scenarios studied consist of above-ground, horizontal, steady-state discharges of dense-phase carbon dioxide (CO2), with orifices ranging in diameter from 1/2 to 2 inch and the liquid CO2 stagnation conditions maintained at between 100 and 150 bar. These scenarios are relevant in scale to leaks from large diameter above-ground pipes or vessels. Seven model input parameters are varied: the vessel temperature and pressure, orifice size, wind speed, humidity, ground surface roughness and height of the release. The input parameters that have a dominant effect on the dispersion distance of the CO2 cloud are identified, both in terms of their direct effect on the dispersion distance and their indirect effect, through interactions with other varying input parameters. The analysis, including the Phast simulations, runs on a standard office laptop computer in less than 30 min. Tests are performed to confirm that a hundred Phast runs are sufficient to produce an emulator with an acceptable degree of accuracy. Increasing the number of Phast runs is shown to have no effect on the conclusions of the sensitivity analysis. The study demonstrates that Bayesian analysis of model sensitivity can be conducted rapidly and easily on consequence models such as Phast. There is the potential for this to become a routine part of consequence modelling. Crown Copyright (C) 2013 Published by Elsevier Ltd. All rights reserved.