When the diameter of the vent gets up over to 5/64 to 3/32" is when I start thinking to change, or if I see signs like blowing grains of powder out the vent when I ram the ball down the bore, or the jet of flame ignites any article of clothing worn by the guy to the right of me on the firing line. For percussion, being able to get a drill bit or wire of 1/32" (if I remember the rule of thumb correctly) diameter all the way through the nipple, or cues like hammer blowback.