Actor Paul McCrane revealed that his character Dr Robert Romano's helicopter death on ER was planned as a sudden surprise for viewers during sweeps time.
The death occurred in Season 10 during the episode titled Freefall. Romano, played by McCrane from Season 4 onward, was crushed by a crashing helicopter at Cook County General Hospital.
McCrane told TV Guide that NBC wanted the moment to deliver maximum impact. "It was sweeps time, and they wanted it to be a shocking surprise," he said. "If they had played up anything about it, it would have diminished the impact of it."
The episode ranked as the third-highest rated of the season. Romano's earlier helicopter accident in Season 9, which severed his arm, had provided some foreshadowing.
McCrane added that the writers likely chose to end the character before he overstayed his welcome. "I sure feel the same way about that," he said.