Do I need to report my overnight stay in Bangkok to Phuket immigration when I have a non-B visa and work permit?

As a rule the immigration offices that require people to file a TM.30 form only make you do a new one when you come back from overseas and get back to your house.

So the answer is NO, unless you're comin' back from overseas you don't need to go file a TM.30 at the Phuket Immigration office.

That you haven't ever done one before has no bearing on the fact you are obligated to do one if you are in the zone that is serviced by the Phuket Immigration office. They are hard core about foreigners in their zone filing one. In fact I doubt you'll get a new extension if you haven't got the TM.30 receipt once your extension comes up.