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Have you checked your PCV valve for proper operation?I'm having to drain it every day now.
If I don't keep it drained, I get a tapping sound on start up that doesn't go away. If I drain it, the tapping sound goes away within the first few minutes of driving. I have ready elsewhere that the PCV valves can make noise too which would make sense. If the catch can is full of water, the vacuum won't be strong enough to open the PCV valve properly, and the ball valve inside the PCV may rattle.
However, I'm concerned it's more than that. The tapping sound is very regular indicating a lifter may be getting sluggish. I can't think of anything else that could be making such a noise that is related to the PCV not scavenging oil vapours properly.
Given all this, I may be better off deleting my catch can if I am unable to keep it drained.